Concentrated quaternary ammonium fabric softener compositions containing cationic polymers

ABSTRACT

The present invention relates to aqueous stable, preferably concentrated, aqueous liquid textile softening compositions comprising fabric softener active and cationic polymer in the continuous aqueous phase to provide improved softening. The compositions of the present invention preferably contain diester quaternary ammonium compounds wherein the fatty acyl groups have an Iodine Value of from greater than about 5 to less than about 140. The cationic polymers can provide additional benefits such as dye transfer inhibition, chlorine scavenging to protect fabrics, cotton soil release benefits, etc.

This application claims the benefit of provisional application No.60/026,442 filed Sep. 19, 1996.

TECHNICAL FIELD

The present invention relates to stable, homogeneous, preferablyconcentrated, aqueous liquid textile treatment compositions containingsoftening compounds, preferably, biodegradable, and cationic polymers.In particular, it especially relates to textile softening compositionsfor use in the rinse cycle of a textile laundering operation to provideexcellent fabric softening/static control benefits, as well as a rangeof other benefits, the compositions being characterized by excellentstorage and viscosity stability, as well as, superior fabric softeningperformance.

BACKGROUND OF THE INVENTION

The art discloses many problems associated with formulating andpreparing stable fabric conditioning formulations. See, for example,U.S. Pat. No. 3,904,533, Neiditch et al. issued Sept. 9, 1975. JapaneseLaid Open Publication 1,249,129, filed Oct. 4, 1989, discloses a problemwith dispersing fabric softener actives containing two long hydrophobicchains interrupted by ester linkages (“diester quaternary ammoniumcompounds”) and solves it by rapid mixing. U.S. Pat. No. 5,066,414,Chang, issued Nov. 19, 1991, teaches and claims compositions containingmixtures of quaternary ammonium salts containing at least one esterlinkage, nonionic surfactant such as a linear alkoxylated alcohol, andliquid carrier for improved stability and dispersibility. U.S. Pat. No.4,767,547, Straathof et al., issued Aug. 30, 1988, claims compositionscontaining either diester, or monoester quaternary ammonium compoundswhere the nitrogen has either one, two, or three methyl groups,stabilized by maintaining a critical low pH of from 2.5 to 4.2.

U.S. Pat. No. 4,401,578, Verbruggen, issued Aug. 30, 1983 discloseshydrocarbons, fatty acids, fatty acid esters, and fatty alcohols asviscosity control agents for fabric softeners (the fabric softeners aredisclosed as optionally comprising ester linkages in the hydrophobicchains). WO 89/115 22-A (DE 3,818,061-A; EP-346,634-A), with a priorityof May 27, 1988, discloses diester quaternary ammonium fabric softenercomponents plus a fatty acid. European Pat. No. 243,735 disclosessorbitan esters plus diester quaternary ammonium compounds to improvedispersions of concentrated softener compositions.

Diester quaternary ammonium compounds with a fatty acid, alkyl sulfate,or alkyl sulfonate anion are disclosed in European Pat. No. 336,267-Awith a priority of Apr. 2, 1988. U.S. Pat. No. 4,808,321, Walley, issuedFeb. 28, 1989, teaches fabric softener compositions comprising monoesteranalogs of ditallow dimethyl ammonium chloride which are dispersed in aliquid carrier as sub-micron particles through high shear mixing, orparticles can optionally be stabilized with emulsifiers such as nonionicC₁₄₋₁₈ ethoxylates.

E.P. Appln. 243,735, Nusslein et al., published Nov. 4, 1987, disclosessorbitan ester plus diester quaternary ammonium compounds to improvedispersibility of concentrated dispersions.

E.P. Appln. 409,502, Tandela et al., published Jan. 23, 1991, discloses,e.g., ester quaternary ammonium compounds, and a fatty acid material orits salt.

E.P. Appln. 240,727, Nusslein et al., priority date of Mar. 12, 1986,teaches diester quaternary ammonium compounds with soaps or fatty acidsfor improved dispersibility in water.

The art also teaches compounds that alter the structure of diesterquaternary ammonium compounds by substituting, e.g., a hydroxy ethyl fora methyl group or a polyalkoxy group for the alkoxy group in the twohydrophobic chains. Specifically, U.S. Pat. No. 3,915,867, Kang et al.,issued Oct. 28, 1975, discloses the substitution of a hydroxyethyl groupfor a methyl group. A softener material with specific cis/trans contentin the long hydrophobic groups is disclosed in Jap. Pat. Appln.63-194316, filed Nov. 21, 1988. Jap. Pat. Appln. 4-333,667, publishedNov. 20, 1992, teaches liquid softener compositions containing diesterquaternary ammonium compounds having a total saturated:unsaturated ratioin the ester allyl groups of 2:98 to 30:70.

The art teaches the addition of cationic polymers to rinse added fabricsoftening compositions for a variety of benefits. U.S. Pat. No.4,386,000, (EPA 0,043,622), Turner, Dovey, and Macgilp, discloses suchpolymers as part of a viscosity control system in relativelyconcentrated compositions containing relatively non-biodegradablesoftener actives. U.S. Pat. No. 4,237,016, (EPA 0,002,085), Rudkin,Clint, and Young, disclose such materials as part of softeningcompositions with low levels of relatively non-biodegradable fabricsoftening actives to make them more effective and to allow substitutionof nonionic fabric softening actives for part of the softener. U.S. Pat.No. 4,179,382, Rudkin, Clint, and Young, also discloses the softenerimprovement that can be obtained with relatively non-biodegradablefabric softener actives by incorporating cationic polymers. Recently, ithas also been discovered that such polymers also can improve dyefastness, protect fabrics against residual hypochlorite bleach etc.

All of the above patents and patent applications are incorporated hereinby reference.

SUMMARY OF THE INVENTION

The present invention provides textile softening compositions withexcellent static control, softening, dye protection, and/or bleachprotection, having good storage stability for concentrated aqueouscompositions and improved performance. In addition, these compositionsprovide these benefits under worldwide laundering conditions andminimize the use of extraneous ingredients for stability and staticcontrol to decrease environmental chemical load.

The fabric softening compounds of the present invention are quaternaryammonium compounds, preferably relatively biodegradable, due to theircontaining ester and/or amide linkages, preferably ester linkages,wherein the fatty acyl groups (1) preferably have an IV of from greaterthan about 5 to less than about 140, (2) preferably a cis/trans isomerweight ratio of greater than about 30/70 when the IV is less than about25, and/or (3) the level of unsaturation preferably being less thanabout 65% by weight, wherein said compounds are capable of formingconcentrated aqueous compositions with concentrations greater than about13% by weight.

The compositions can be aqueous liquids, preferably concentrated,containing from about 2% to about 60%, preferably from about 10% toabout 50%, more preferably from about 15% to about 40%, and even morepreferably from about 20% to about 35%, of said preferablybiodegradable, preferably diester, softening compound and from about0.001% to about 10%, preferably from about 0.01% to about 5%, morepreferably from about 0.1% to about 2%, of cationic polymer, typicallyhaving a molecular weight of from about 500 to about 1,000,000,preferably from about 1,000 to about 500,000, more preferably from about1,000 to about 250,000, and even more preferably from about 2,000 toabout 100,000 and a charge density of at least about 0.01 meqlgm.,preferably from about 0.1 to about 8 meq/gm., more preferably from about0.5 to about 7, and even more preferably from about 2 to about 6. Inorder to provide the benefits of the cationic polymers, and especiallycationic polymers containing amine, or imine, groups, said cationicpolymer is primarily in the continuous aqueous phase.

DETAILED DESCRIPTION OF THE INVENTION

The Fabric Softening Compounds

The fabric softening compounds can include the relativelynon-biodegradable compounds disclosed in U.S. Pats. Nos. 4,386,000;4,237,016; and 4,179,382, incorporated hereinbefore by reference. Otherfabric softening compounds are disclosed in U.S. Pat. No. 4,103,047,Zaki et al., issued Jul. 25, 1978; U.S. Pat. No. 4,237,155, Kardouche,issued Dec. 2, 1980; U.S. Pat. No. 3,686,025, Morton, issued Aug. 22,1972; U.S. Pat. No. 3,849,435, Diery et al., issued Nov. 19, 1974; andU.S. Pat. No. 4,073,996, Bedenk, issued Feb. 14, 1978; U.S. Pat. No.4,661,269, Toan Trinh, Errol H. Wahl, Donald M. Swartley and Ronald L.Hemingway, issued Apr. 28, 1987; U.S. Pat. No.: 3,408,361, Mannheimer,issued Oct. 29, 1968; U.S. Pat. No. 4,709,045, Kubo et al., issued Nov.24, 1987; U.S. Pat. No. 4,233,451, Pracht et al., issued Nov. 11, 1980;U.S. Pat. No. 4,127,489, Pracht et al., issued Nov. 28, 1979; U.S. Pat.No. 3,689,424, Berg et al., issued Sept. 5, 1972; U.S. Pat. No.4,128,485, Baumann et al., issued Dec. 5, 1978; U.S. Pat. No. 4,161,604,Elster et al., issued Jul. 17, 1979; U.S. Pat. No. 4,189,593, Wechsleret al., issued Feb. 19, 1980; and U.S. Pat. No. 4,339,391, Hoffman etal., issued Jul. 13, 1982, all of said patents being incorporated hereinby reference. However, the preferred fabric softening compounds arebiodegradable, especially as described hereinafter.

(A) Diester/diamido Quaternary Ammonium Compound (DEQA)

The present invention preferably relates to DEQA compounds andcompositions containing DEQA as a component:

DEQA having the formula:

(R)_(4−m)—N⁺—[(CH₂)_(n)—Y—R²]_(m)X⁻

wherein

each Y=—O—(O)C—, or —C(O)—O—, —NR—(O)C—, or —C(O)—NR—, preferably—O—(O)C—, or —C(O)—O—, and more preferably —O—(O)C—;

m=2 or 3;

each n=1 to 4;

each R substituent is a short chain C₁-C₆, preferably C₁-C₃, alkyl orhydroxyalkyl group, e.g., methyl (most preferred), ethyl,2-hydroxyethyl, propyl, and the like, benzyl or mixtures thereof;

each R² is a long chain, preferably at least partially unsaturated [IVpreferably greater than about 5 to less than about 140, preferably fromabout 40 to about 140, more preferably from about 60 to about 130; andmost preferably from about 70 to about 105 (As used herein, the IodineValue of the “parent” fatty acid, or “corresponding” fatty acid, is usedto define an average level of unsaturation for all of the R¹ groups thatare present, that is the same as the level of unsaturation that would bepresent in fatty acids containing the same R¹ groups.)], C₁₁-C₂₁hydrocarbyl, or substituted hydrocarbyl substituent and the counterion,X⁻, can be any softener-compatible anion, for example, chloride,bromide, methylsulfate, formate, sulfate, nitrate and the like.

DEQA compounds prepared with fully saturated acyl groups are rapidlybiodegradable and excellent softeners. However, compounds prepared withat least partially unsaturated acyl groups have many advantages (i.e.,concentratability and good storage viscosity) and are highly acceptablefor consumer products when certain conditions are met. When suchcompounds are formulated at high concentrations and the cationicpolymers are present, the compositions containing even such compoundstend to be unstable. At lower concentrations, the cationic fabricsoftener actives can be more, or completely, saturated, and can be lessreadily biodegradable, like those disclosed in U.S. Pat. Nos.:4,386,000; 4,237,016; and 4,179,382, incorporated hereinbefore byreference, but these options are not desirable, due to the desire tolimit the use of such materials.

Variables that can be adjusted to obtain the benefits of usingunsaturated acyl groups include the Iodine Value (IV) of the fattyacids; the cis/trans isomer weight ratios in the fatty acyl groups; andthe odor of fatty acid and/or the DEQA. Any reference to IV hereinafterrefers to IV of fatty acyl groups and not to the resulting DEQAcompound.

When the IV of the fatty acyl groups is above about 20, the DEQAprovides excellent antistatic effect. Antistatic effects are especiallyimportant where the fabrics are dried in a tumble dryer, and/or wheresynthetic materials which generate static are used. Maximum staticcontrol occurs with an IV of greater than about 20, preferably greaterthan about 40. When fully saturated DEQA compositions are used, poorstatic control results. Also, as discussed hereinafter,concentratability increases as IV increases. The benefits ofconcentratability include: use of less packaging material; use of lessorganic solvents, especially volatile organic solvents; use of lessconcentration aids which may add nothing to performance; etc.

As the IV is raised, there is a potential for odor problems.Surprisingly, some highly desirable, readily available sources of fattyacids such as tallow, possess odors that remain with the compound DEQAdespite the chemical and mechanical processing steps which convert theraw tallow to finished DEQA. Such sources must be deodorized, e.g., byabsorption, distillation (including stripping such as steam stripping),etc., as is well known in the art. In addition, care must be taken tominimize contact of the resulting fatty acyl groups to oxygen and/orbacteria by adding antioxidants, antibacterial agents, etc. Theadditional expense and effort associated with the unsaturated fatty acylgroups is typically justified by the superior concentratability and/orperformance.

DEQA derived from highly unsaturated fatty acyl groups, i.e., fatty acylgroups having a total unsaturation above about 65% by weight can providebenefits such as improved water absorbency of the fabrics. In general,an IV range of from about 40 to about 140 is preferred forconcentratability, maximization of fatty acyl sources, excellentsoftness, static control, etc.

Highly concentrated aqueous dispersions of these diester compounds cangel and/or thicken during low (40° F) temperature storage. Diestercompounds made from only unsaturated fatty acids minimizes this problembut additionally is more likely to cause malodor formation.Surprisingly, compositions from these diester compounds made from fattyacids having an IV of from about 5 to about 25, preferably from about 10to about 25, more preferably from about 15 to about 20, and a cis/transisomer weight ratio of from greater than about 30/70, preferably greaterthan about 50/50, more preferably greater than about 70/30, are storagestable at low temperature with minimal odor formation. These cis/transisomer weight ratios provide optimal concentratability at these IVranges. In the IV range above about 25, the ratio of cis to transisomers is less important unless higher concentrations are needed. Therelationship between IV and concentratability is described hereinafter.For any IV, the concentration that will be stable in an aqueouscomposition will depend on the criteria for stability (e.g., stable downto about 5° C.; stable down to 0° C., doesn't gel; gels but recovers onheating, etc.) and the other ingredients present, but the concentrationthat is stable can be raised by adding the concentration aids, describedhereinafter in more detail, to achieve the desired stability. However,as described hereinafter, when the cationic polymer is present, thelevel, and identity of the polymer affect the stability, and theselection must be made to provide the desired stability according to thecriteria disclosed herein.

Generally, hydrogenation of fatty acids to reduce polyunsaturation andto lower IV to insure good color and improve odor and odor stabilityleads to a high degree of trans configuration in the molecule.Therefore, diester compounds derived from fatty acyl groups having lowIV values can be made by mixing fully hydrogenated fatty acid with touchhydrogenated fatty acid at a ratio which provides an IV of from about 5to about 25. The polyunsaturation content of the touch hardened fattyacid should be less than about 5%, preferably less than about 1%. Duringtouch hardening the cis/trans isomer weight ratios are controlled bymethods known in the art such as by optimal mixing, using specificcatalysts, providing high H₂ availability, etc. Touch hardened fattyacid with high cis/trans isomer weight ratios is available commercially(i.e., Radiacid 406 from FINA).

It has also been found that for good chemical stability of the diesterquaternary compound in molten storage, moisture level in the rawmaterial should be controlled and minimized preferably less than about1% and more preferably less than about 0.5% water. Storage temperaturesshould be kept as low as possible and still maintain a fluid material,ideally in the range of from about 120° F. to about 150° F. The optimumstorage temperature for stability and fluidity depends on the specificIV of the fatty acid used to make the diester quaternary and thelevel/type of solvent selected. It is important to provide good moltenstorage stability to provide a commercially feasible raw material thatwill not degrade noticeably in the normaltransportation/storage/handling of the material in manufacturingoperations.

Compositions of the present invention preferably contain the followinglevels of DEQA: from about 5% to about 50%, preferably from about 15% toabout 40%, more preferably from about 15% to about 35%, and even morepreferably from about 15% to about 32%.

It will be understood that substituents R and R² can optionally besubstituted with various groups such as alkoxyl or hydroxyl groups. Thepreferred compounds can be considered to be diester variations ofditallow dimethyl ammonium chloride (DTDMAC), which is a widely usedfabric softener. At least 80% of the DEQA is in the diester form, andfrom 0% to about 20%, preferably less than about 10%, more preferablyless than about 6%, can be DEQA monoester (e.g., only one —Y—R² group).

As used herein, when the diester is specified, it will include themonoester that is normally present. The level of monoester present canbe controlled in the manufacturing of the DEQA. For softening, underno/low detergent carry-over laundry conditions the percentage ofmonoester should be as low as possible, preferably no more than about2.5%. The cationic polymer typically allows this same materialcontaining only low levels of monoester to be used, even under detergentcarry-over conditions. Only low levels of cationic polymer are neededfor this purpose, i.e., ratios of fabric softener active to polymer offrom about 1000:1 to about 2.5:1, preferably from about 500:1 to about20:1, more preferably from about 200:1 to about 50:1. Under highdetergent carry-over conditions, the ratio is preferably about 100:1.

The following are non-limiting examples (wherein all long-chain alkylsubstituents are straight-chain):

Saturated

[HO—CH(CH₃)CH₂][CH₃]⁺N[CH₂CH₂OC(O)C₁₅H₃₁]₂Br⁻

[C₂H₅]₂N⁺[CH₂CH₂OC(O)C₁₇H₃₅]₂Cl⁻

[CH₃][C₂H₅]⁺N[CH₂CH₂OC(O)C₁₃H₂₇]₂I⁻

[C₃H₇][C₂H₅]⁺N[CH₂CH₂OC(O)C₁₅H₃₁]₂SO₄—CH3

[CH₃]₂ ⁺N—[CH₂CH₂OC(O)C₁₅H₃₁][CH₂CH₂OC(O)C₁₇H₃₅]Cl⁻

[CH₃]₂ ⁺N[CH₂CH₂OC(O)R²]₂Cl⁻

where —C(O)R² is derived from saturated tallow.

Unsaturated

[HO—CH(CH₃)CH₂][CH₃]⁺N[CH₂CH₂OC(O)C₁₅H₂₉]₂Br⁻

[C₂H₅]₂ ⁺N[CH₂CH₂OC(O)C₁₇H₃₃]₂Cl⁻

[CH₃][C₂H₅]⁺N[CH₂CH₂OC(O)C₁₃H₂₅]₂I⁻

[C₃H₇][C₂H₅]⁺N[CH₂CH₂OC(O)C₁₅H₂₄]₂SO₄—CH₃

[CH₃]₂ ⁺N—[CH₂CH₂OC(O)C₁₅H₂₉][CH₂CH₂OC(O)C₁₇H₃₃]Cl⁻

[CH₂CH₂OH][CH₃]⁺N[CH₂CH₂OC(O)R²]₂Cl⁻

[CH₃]₂ ⁺N[CH₂CH₂OC(O)R²]₂Cl⁻

where —C(O)R² is derived from partially hydrogenated tallow or modifiedtallow having the characteristics set forth herein.

In addition, since the foregoing compounds (diesters) are somewhatlabile to hydrolysis, they should be handled rather carefully when usedto formulate the compositions herein. For example, stable liquidcompositions herein are formulated at a pH in the range of from about 2to about 5, preferably from about 2 to about 4.5, more preferably fromabout 2.5 to about 4. For best product odor stability, when the IV isgreater that about 25, the pH is from about 2.8 to about 3.5, especiallyfor “unscented” (no perfume) or lightly scented products. This appearsto be true for all DEQAs, but is especially true for the preferred DEQAspecified herein, i.e., having an IV of greater than about 20,preferably greater than about 40. The limitation is more important as IVincreases. The pH can be adjusted by the addition of a Bronsted acid.The pH ranges above are determined without prior dilution of thecomposition with water.

Examples of suitable Bronsted acids include the inorganic mineral acids,carboxylic acids, in particular the low molecular weight (C₁-C₅)carboxylic acids, and alkylsulfonic acids. Suitable inorganic acidsinclude HCl, H₂SO₄, HNO₃ and H₃PO₄. Suitable organic acids includeformic, acetic, methylsulfonic and ethylsulfonic acid. Preferred acidsare hydrochloric, phosphoric, and citric acids.

(B) Cationic Polymer

The cationic polymers of the present invention can be amine salts orquaternary ammonium salts. Preferred are quaternary ammonium salts. Theyinclude cationic derivatives of natural polymers such as somepolysaccharide, gums, starch and certain cationic synthetic polymerssuch as polymers and co-polymers of cationic vinyl pyridine or vinylpyridinium halides. Preferably the polymers are water soluble, forinstance to the extent of at least 0.5% by weight at 20° C. Preferablythey have molecular weights of from about 600 to about 1,000,000, morepreferably from about 600 to about 500,000, even more preferably fromabout 800 to about 300,000, and especially from about 1000 to 10,000. Asa general rule, the lower the molecular weight the higher the degree ofsubstitution (D.S.) by cationic, usually quaternary groups, which isdesirable, or, correspondingly, the lower the degree of substitution thehigher the molecular weight which is desirable, but no preciserelationship appears to exist. In general, the cationic polymers shouldhave a charge density of at least about 0.01 meq/gm., preferably fromabout 0.1 to about 8 meq/gm., more preferably from about 0.5 to about 7,and even more preferably from about 2 to about 6.

Suitable desirable cationic polymers are disclosed in “CTFAInternational Cosmetic Ingredient Dictionary”, Fourth Edition, J. M.Nikitakis, et al, Editors, published by the Cosmetic, Toiletry, andFragrance Association, 1991, incorporated herein by reference. The listincludes the following:

Polyquaternium-1

CAS Number: 68518-54-7

Definition: Polyquaternium-1 is the polymeric quaternary ammonium saltthat conforms generally to the formula:

{(HOCH₂CH₂)₃N⁺—CH₂CH═CHCH₂—[N⁺(CH₃)₂—CH₂CH═CHCH₂]_(x)—N⁺(CH₂CH₂OH)₃}[Cl⁻]_(x+2)

Polyquaternium-2

CAS Number: 63451-274

Definition: Polyquaternium-2 is the polymeric quaternary ammonium saltthat conforms generally to the formula:

[—N(CH₃)₂—CH₂CH₂CH₂—NH—C(O)—NH—CH₂CH₂CH₂—N(CH₃)₂—CH₂CH₂OCH₂CH₂—]²⁺(Cl⁻)₂

Other Names: Mirapol A-15 (Rhône-Poulenc)

Polyquaternium-4

Definition: Polyquaternium-4 is a copolymer of hydroxyethylcellulose anddiallyldimethyl ammonium chloride.

Other Names:

Celquat H 100 (National Starch)

Celquat L200 (National Starch)

Diallyldimonium Chloride/Hydroxyethyl-cellulose Copolymer

Polyquaternium-5

CAS Number: 26006-224

Definition: Polyquaternium-5 is the copolymer of acrylamide andbeta-methacrylyloxyethyl trimethyl ammonium methosulfate.

Other Names:

Ethanaminium, N,N,N-Trimethyl-N-2-[(2-Methyl-1-Oxo-2-Propenyl)Oxy]-,Methyl Sulfate, Polymer with 2-Propenamide

Nalco 7113 (Nalco)

Quaternium-39

Reten 210 (Hercules)

Reten 220 (Hercules)

Reten 230 (Hercules)

Reten 240 (Hercules)

Reten 1104 (Hercules)

Reten 1105 (Hercules)

Reten 1106 (Hercules)

Polyquaternium-6

CAS Number: 26062-79-3

Empirical Formula: (C₈H₁₆N.Cl)_(x)

Definition: Polyquaternium-6 is a polymer of dimethyl diallyl ammoniumchloride.

Other Names:

Agequat-400 (CPS)

Conditioner P6 (3V-SIGMA)

N,N-Dimethyl-N-2-Propenyl-2-Propen-1-aminium Chloride, Homopolymer

Hoe S 3654 (Hoechst AG)

Mackernium 006 (McIntyre)

Merquat 100 (Calgon)

Nalquat 6-20 (Nalco)

Poly-DAC 40 (Rhône-Poulenc)

Poly(Dimethyl Diallyl Ammonium Chloride)

Poly(DMDAAC)

2-Propen-1-aminium, N,N-Dimethyl-N-2-Propenyl-, Chloride, Homopolymer

Quaternium-40

Salcare SC30 (Allied Colloids)

Polyquaternium-7

CAS Number: 26590-05-6

Empirical Formula: (C₈H₁₆N.C₃H₅NO.Cl)_(x)

Definition: Polyquaternium-7 is the polymeric quaternary ammonium saltconsisting of acrylamide and dimethyl diallyl ammonium chloridemonomers.

Other Names:

Agequat-500 (CPS)

Agequat-5008 (CPS)

Agequat C-505 (CPS)

Conditioner P7 (3V-SIGMA)

N,N-Dimethyl-N-2-Propenyl-2-Propen-1-aminium Chloride, Polymer with2-Propenamide

Mackernium 007 (McIntyre)

Merquat 550 (Calgon)

Merquat S (Calgon)

2-Propen-1-aminium, N,N-Dimethyl-N-2-Propenyl-, Chloride, Polymer with2-Propenamide

Quaternium-41

Salcare SC10 (Allied Colloids)

Polyquaternium-8

Definition: Polyquaternium-8 is the polymeric quaternary ammonium saltof methyl and stearyl dimethylaminoethyl methacrylate quaternized withdimethyl sulfate.

Other Names:

Methyl and Stearyl Dimethylaminoethyl Methacrylate Quaternized withDimethyl Sulfate Quaternium-42

Polyquaternium-9

Definition: Polyquaternium-9 is the polymeric quaternary ammonium saltof polydimethylaminoethyl methacrylate quaternized with methyl bromide.

Other Names:

Polydimethylaminoethyl Methacrylate Quaternized with Methyl BromideQuaternium-49

Polyquaternium-10

CAS Numbers: 53568-66-4; 55353-19-0; 54351-50-7; 81859-24-7; 68610-92-4;81859-24-7

Definition: Polyquaternium-10 is a polymeric quaternary ammonium salt ofhydroxyethyl cellulose reacted with a trimethyl ammonium substitutedepoxide.

Other Names:

Cellulose, 2-[2-Hydroxy-3-Trimethylammono)propoxy]Ethyl ether, chloride

Celquat SC-240 (National Starch)

Quaternium-19

UCARE Polymer JR-125 (Amerchol)

UCARE Polymer JR-400 (Amerchol)

UCARE Polymer JR-30M (Amerchol)

UCARE Polymer LR 400 (Amerchol)

UCARE Polymer LR 30M (Amerchol)

Ucare Polymer SR-10 (Amerchol)

Polyquaternium-11

Empirical Formula: (C₈H₁₅NO₂.C₆H₉NO)_(x).xC₄H₁₀O₄S

Definition: Polyquaternium-11 is a quaternary ammonium polymer formed bythe reaction of diethyl sulfate and a copolymer of vinyl pyrrolidone anddimethyl aminoethylmethacrylate.

Other Names:

Gafquat 734 (GAF)

Gafquat 755 (GAF)

Gafquat 755N (GAF)

2-Propenol Acid, 2-Methyl-2-(Dimethylamino)Ethyl Ester, Polymer and1-Ethenyl-2-Pyrrolidinone, Compound with Diethyl Sulfate

2-Pyrrolidinone, 1-Ethenyl-Polymer and 2-(Dimethylamino)Ethyl2-Methyl-2-Propenoate, Compound and Diethyl Sulfate

2-Pyrrolidinone, 1-Ethenyl-, Polymer and 2-Dimethylamino)Ethyl2-Methyl-2-Propenoate, compound with Diethyl Sulfate

Quaternium-23

Polyquaternium-12

CAS Number: 68877-50-9

Definition: Polyquaternium-12 is a polymeric quaternary ammonium saltprepared by the reaction of ethyl methacrylate/abietylmethacrylate/diethylaminoethyl methacrylate copolymer with dimethylsulfate.

Other Names:

Ethyl Methacrylate/Abietyl Methacrylate/Diethylaminoethyl

Methacrylate-Quaternized with Dimethyl Sulfate

Quaternium-37

Polyquaternium-13

CAS Number: 68877-47-4

Definition: Polyquaternium-13 is a polymeric quaternary ammonium saltprepared by the reaction of ethyl methacrylate/oleylmethacrylate/diethylaminoethyl methacrylate copolymer with dimethylsulfate.

Other Names:

Ethyl Methacrylate/Oleyl Methacrylate/DiethylaminoethylMethacrylate-Quaternized with Dimethyl Sulfate

Quaternium 38

Polyquaternium-14

CAS Number: 27103-90-8

Definition: Polyquaternium-14 is the polymeric quaternary ammonium saltthat conforms generally to the formula:

—{—CH₂C—(CH₃)—[C(O)O—CH₂CH₂—N(CH₃)₃—]}_(x) ⁺[CH₃SO₄]⁻x

Other Names:

Ethanaminium, N,N,N-Trimethyl-2-[(2-Methyl-1-Oxo-2-Propenyl)Oxy]-,Methyl Sulfate,

Homopolymer

Reten 300 (Hercules)

Polyquaternium-15

CAS Number: 35429-19-7

Definition: Polyquaternium-15 is the copolymer of acrylamide andbetamethacrylyloxyethyl trimethyl ammonium chloride.

Other Names:

Rohagit KF 400 (Rohm GmbH)

Rohagit KF 720 (Rohm GmbH)

Polyquaternium-16

Definition: Polyquaternium-16 is a polymeric quaternary ammonium saltformed from methylvinylimidazolium chloride and vinylpyrrolidone.

Other Names:

Luviquat FC 370 (BASF)

Luviquat FC 550 (BASF)

Luviquat FC 905 (BASF)

Luviquat HM-552 (BASF)

Polyquaternium-17

Definition: Polyquaternium-17 is; a polymeric quaternary salt preparedby the reaction of adipic acid and dimethylaminopropylamine, reactedwith dichloroethyl ether. It conforms generally to the formula:

—[—N⁺(CH₂)₃NH(O)C—(CH₂)₄—C(O)NH—(CH₂)₃—N(CH₃)₂—(CH₂)₂—O—(CH₂)₂—]_(x)Cl⁻_(x)

Other Names:

Mirapol AD-1 (Rhône-Poulenc)

Polyquaternium-18

Definition: Polyquaternium-18 is a polymeric quaternary salt prepared bythe reaction of azelaic acid and dimethylaminopropylamine reacted withdichloroethyl ether. It conforms generally to the formula:

—[—N⁺(CH₂)₃NH—(O)C—(CH₂)₃C(O)—NH—(CH₂)₃—N(CH₃)₂—(—CH₂)₂—O—(CH₂)₂—]_(x)Cl⁻_(x)

Other Names:

Mirapol AZ-1 (Rhône-Poulenc)

Polyquaternium-19

Definition: Polyquaternium-19 is the polymeric quaternary ammonium saltprepared by the reaction of polyvinyl alcohol with 2,3-epoxypropylamine.

Other Names:

Arlatone PQ-220 (ICI Americas)

Polyquaternium-20

Definition: Polyquaternium-20 is the polymeric quaternary ammonium saltprepared by the reaction of polyvinyl octadecyl ether with2,3-epoxypropylamine.

Other Names:

Arlatone PQ-225 (ICI Americas)

Polyquaternium-22

CAS Number: 53694-17-0

Empirical Formula: (C₈H₁₆NCl) (C₃H₃O₂)

Definition: Polyquaternium-22 is a copolymer of dimethyldiallyl ammoniumchloride and acrylic acid. It conforms generally to the formula:

—[DMDA]_(x)—[—CH₂CH(C(O)OH)—]_(y)— where —[DMDA]_(x)— is:

Other Names:

Merquat 280 (Calgon)

Polyquaternium-24

Definition: Polyquaternium-24 is a polymeric quaternary ammonium salt ofhydroxyethyl cellulose reacted with a lauryl dimethyl ammoniumsubstituted epoxide.

Other Names:

Quatrisoft Polymer LM-200 (Amerchol)

Polyquaternium-27

Definition: Polyquaternium-27 is the block copolymer formed by thereaction of Polyquaternium-2 with Polyquaternium-17.

Other Names:

Mirapol 9 (Rhône-Poulenc)

Mirapol-95 (Rhône-Poulenc)

Mirapol 175 (Rhône-Poulenc)

Polyquaternium-28

Definition: Polyquaternium-28 is a polymeric quaternary ammonium saltconsisting of vinylpyrrolidone and dimethylaminopropyl methacrylamidemonomers. It conforms generally to the formula:

—{VP}_(x)—{—CH₂—CH(CH₃)[C(O)—NH—CH₂CH₂CH₂N³⁰ (CH₃)₃—]}_(y)Cl⁻ _(y) where[VP] is:

Other Names:

Gafquat HS-100 (GAF)

Vinylpyrrolidone/Methacrylamidopropyltrimethylammonium ChlorideCopolymer.

Polyquaternium-29

Definition: Polyquaternium-29 is Chitosan that has been reacted withpropylene oxide and quaternized with epichlorohydrin.

Other Names:

Lexquat CH (Inolex).

Polyquaternium-30

Definition: Polyquaternium-30 is the polymeric quaternary ammonium saltthat conforms generally to the formula:

—[CH₂C(CH₃)(C(O)OCH₃)]_(x)—[CH₂C(CH₃)(C(O)OCH₂CH₂N⁺(CH₃)₂CH₂COO⁻)]_(y)—

Other Names:

Mexomere PX (Chimex)

Of the polysaccharide gums, guar and locust bean gums, which aregalactomannam gums are available commercially, and are preferred. Thusguar gums are marketed under Trade Names CSAA M/200, CSA 200/50 byMeyhall and Stein-Hall, and hydroxyalkylated guar gums are availablefrom the same suppliers. Other polysaccharide gums commerciallyavailable include: Xanthan Gum; Ghatti Gum; Tamarind Gum; Gum Arabic;and Agar.

Cationic guar gums and methods for making them are disclosed in BritishPat. No. 1,136,842 and U.S. Pat. No. 4,031,307. Preferably they have aD.S. of from 0.1 to about 0.5.

An effective cationic guar gum is Jaguar C-13S (Trade Name—Meyhall),believed to be derived from guar gum of molecular weight about 220,000,and to have a degree of substitution about 0.13, wherein the cationicmoiety has the formula:

—CH₂CH(OH)CH₂N⁺(CH₃)₃Cl⁻

Very effective also is guar gum quaternized to a D.S. of about 0.2 to0.5 with the quaternary grouping:

—CH₂CH(OH)CH₂N⁺(CH₃)₃Cl⁻

or

—CH₂CH═CHCH₂N⁺(CH₃)₃Cl⁻

Cationic guar gums are a highly preferred group of cationic polymers incompositions according to the invention and act both as scavengers forresidual anionic surfactant and also add to the softening effect ofcationic textile softeners even when used in baths containing little orno residual anionic surfactant. The cationic guar gums are effective atlevels from about 0.03 to 0.7% by weight of the compositions preferablyup to 0.4%.

The other polysaccharide-based gums can be quaternized similarly and actsubstantially in the same way with varying degrees of effectiveness.Suitable starches and derivatives are the natural starches such as thoseobtained from maize, wheat, barley etc., and from roots such as potato,tapioca etc., and dextrins, particularly the pyrodextrins such asBritish gum and white dextrin.

In particular, cationic dextrins such as the above, which have molecularweights (as dextrins) in the range from about 1,000 to about 10,000,usually about 5,000, are effective scavengers for anionic surfactants.Preferably the D.S. is in the range from 0.1 upwards, especially fromabout 0.2 to 0.8. Also suitable are cationic starches, especially thelinear fractions, amylose, quaternized in the usual ways. Usually theD.S. is from 0.01 to 0.9, preferably from 0.2 to 0.7, that is ratherhigher than in most conventional cationic starches.

The cationic dextrins usually are employed at levels in the range fromabout 0.05 to 0.7% of the composition, especially from about 0.1 to0.5%. Polyvinyl pyridine and co-polymers thereof with for instancestyrene, methyl methacrylate, acrylamides, N-vinyl pyrrolidone,quaternized at the pyridine nitrogens are very effective, and can beemployed at even lower levels than the polysaccharide derivativesdiscussed above, for instance at 0.01 to 0.2% by weight of thecomposition, especially from 0.02 to 0.1%. In some instances theperformance seems to fall off when the content exceeds some optimumlevel such as about 0.05% by weight for polyvinyl pyridinium chlorideand its co-polymer with styrene.

Some very effective individual cationic polymers are the following:Polyvinyl pyridine, molecular weight about 40,000, with about 60% of theavailable pyridine nitrogens quaternized; Co-polymer of 70/30 molarproportions of vinyl pyridine/styrene, molecular weight about 43,000,with about 45% of the available pyridine nitrogens quaternized as above;Co-polymers of 60/40 molar proportions of vinyl pyridine/acrylamide,with about 35% of the available pyridine nitrogens quaternized as above.Co-polymers of 77/23 and 57/43 molar proportions of vinylpyridine/methyl methacrylate, molecular weight about 43,000, with about97% of the available pyridine nitrogens quaternized as above.

These cationic polymers are effective in the compositions at very lowconcentrations for instance from 0.001% by weight to 0.2% especiallyfrom about 0.02% to 0.1%. In some instances the effectiveness seems tofall off, when the content exceeds some optimum level, such as forpolyvinyl pyridine and its styrene co-polymer about 0.05%.

Some other effective cationic polymers are: Co-polymer of vinyl pyridineand N-vinyl pyrrolidone (63/37) with about 40% of the available pyridinenitrogens quaternized; Co-polymer of vinyl pyridine and acrylonitrile(60/40), quaternized as above; Co-polymer of N,N-dimethyl amino ethylmethacrylate and styrene (55/45) quaternized as above at about 75% ofthe available amino nitrogens. Eudragit E (Trade Name of Rohm GmbH)quaternized as above at about 75% of the available amino nitrogens.Eudragit E is believed to be co-polymer of N,N-dialkyl amino alkylmethacrylate and a neutral acrylic acid ester, and to have molecularweight about 100,000 to 1,000,000; Co-polymer of N-vinyl pyrrolidone andN,N-diethyl amino methyl methacrylate (40/50), quaternized at about 50%of the available amino nitrogens; These cationic polymers can beprepared in a known manner by quaternizing the basic polymers.

Yet other co-polymers are condensation polymers, formed by thecondensation of two or more reactive monomers both of which arebifunctional. Two broad classes of these polymers can be formed whichare then made cationic, viz. (a) those having a nitrogen atom which canbe cationic in the back bone or which can be made cationic in the backbone.

Compounds of class (a) can be prepared by condensing a tertiary orsecondary amine of formula:

R₁₁N(R₁₂OH)₂

wherein R₁₁ is H or a C₁₋₆ alkyl group, preferably methyl, or R₁₂OH andeach R₁₂ independently is a C₁₋₆ alkylene group, preferably ethylene,with a dibasic acid, or the corresponding acyl halide having formula

XOOC(R₁₃)COOX

or the anhydride thereof, wherein R₁₃ is a C₁₋₆ alkylene, hydroxyalkylene or alkenyl group or an aryl group, and X is H, or a halidepreferably chloride. Some suitable acids are succinic, malic, glutaric,adipic, pimelic, suberic, maleic, ortho-, meta- and tere-phthalic, andtheir mono and di-chlorides. Very suitable anhydrides include maleic andphthalic anhydrides. The condensation leads to polymers having repeatingunits of structure

[—R₁₂—N(R₁₁)—R₁₂—O(O)C—R₁₃—C(O)O—]

Reactions of this sort are described in British Pat. No. 602.048. Thesecan be rendered cationic for instance by addition of an alkyl or alkoylhalide or a di-alkyl sulphate at the back bone nitrogen atoms or at someof them. When R₁₁ is (R₁₂OH) this group can be esterified by reactionwith a carboxylic acid, e.g. a C₁₋₂₀ saturated or unsaturated fatty acidor its chloride or anhydride as long as the resulting polymers remainsufficiently water soluble. When long chain, about R₁₀ and higher, fattyacids are employed these polymers can be described as “comb” polymers.Alternatively when R₁₁ is (R₁₂OH) the R₁₁ groups can be reacted with acationic e.g. a quaternary ammonium group such as glycidyl trimethylammonium chloride or l-chlorobut-2-ene trimethyl ammonium chloride, andlike agents mentioned hereinafter.

Some cationic polymers of this class can also be made by directcondensation of a dicarboxylic acid etc. with a difunctional quaternaryammonium compound having for instance the formula

R₁₁R₁₄N⁺(R₁₂OH)₂Z⁻

where R₁₄ is an H or C₁₋₆ alkyl group, and R₁₁ and R₁₂ are as definedabove, and Z⁻ is an anion.

Another class of copolymer with nitrogens which can be made cationic inthe back bone can be prepared by reaction of a dicarboxylic acid, etc.as defined above with a dialkylene triamine, having structure

H₂NR₁₅N(R₁₇)R₁₆NH₂

where R₁₅ and R₁₆ independently each represent a C₂₋₆ alkylene group,and R₁₇ is hydrogen or a C₁₋₆ alkyl group. This leads to polymers havingthe repeating unit

[—(O)C—R₁₃—C(O)—N—R₁₅—N(R₁₇)—R₁₆—NH—]

wherein the nitrogen not directly linked to a CO group i.e. not an amidenitrogen, can be rendered cationic, as by reaction with an alkyl halideor dialkyl sulphate.

Commercial examples of a condensation polymers believed to be of thisclass are sold under the generic Trade Name Alcostat by Allied Colloids.

Yet other cationic polymeric salts are quaternized polyethyleneimines.These have at least 10 repeating units, some or all being quaternized.

Commercial examples of polymers of this class are also sold under thegeneric Trade Name Alcostat by Allied Colloids.

It will be appreciated by those skilled in the art that thesequaternization and esterification reactions do not easily go tocompletion, and usually a degree of substitution up to about 60% of theavailable nitrogen is achieved and is quite effective. Thus it should beunderstood that usually only some of the units constituting the cationicpolymers have the indicated structures.

Polymers of class (b), with no nitrogen in the back bone can be made byreacting a triol or higher polyhydric alcohol with a dicarboxylic acidetc. as described above, employing glycerol, for example. These polymerscan be reacted with cationic groups at all the hydroxyls, or at some ofthem.

Typical examples of the above types of polymers are disclosed in U.S.Pat. No. 4,179,382, incorporated hereinbefore by reference.

Other cationic polymers of the present invention are water-soluble ordispersible, modified polyamines. The polyamine cationic polymers of thepresent invention are water-soluble or dispersible, modified polyamines.These polyamines comprise backbones that can be either linear or cyclic.The polyamine backbones can also comprise polyamine branching chains toa greater or lesser degree. In general, the polyamine backbonesdescribed herein are modified in such a manner that each nitrogen of thepolyamine chain is thereafter described in terms of a unit that issubstituted, quaternized, oxidized, or combinations thereof.

For the purposes of the present invention the term “modification” isdefined as replacing a backbone —NH hydrogen atom by an E unit(substitution), quaternizing a backbone nitrogen (quaternized) oroxidizing a backbone nitrogen to the N-oxide (oxidized). The terms“modification” and “substitution” are used interchangably when referringto the process of replacing a hydrogen atom attached to a backbonenitrogen with an E unit. Quaternization or oxidation may take place insome circumstances without substitution, but preferably substitution isaccompanied by oxidation or quaternization of at least one backbonenitrogen.

The linear or non-cyclic polyamine backbones that comprise the polyaminecationic polymers of the present invention have the general formula:

[H₂N—R]_(n+1)—[N(H)—R]_(m)—[N(H)—R]_(n)—NH₂

said backbones prior to subsequent modification, comprise primary,secondary and tertiary amine nitrogens connected by R “linking” units.The cyclic polyamine backbones comprising the polyamine cationicpolymers of the present invention have the general formula:

[H₂N—R]_(n−k+1)—[N(H)—R]_(m)—[N(—)—R]_(n)—[N(R)—R]_(k)—NH₂

wherein (—) indicates a covalent bond, said backbones prior tosubsequent modification, comprise primary, secondary and tertiary aminenitrogens connected by R “linking” units

For the purpose of the present invention, primary amine nitrogenscomprising the backbone or branching chain once modified are defined asV or Z “terminal” units. For example, when a primary amine moiety,located at the end of the main polyamine backbone or branching chainhaving the structure

[H₂N—R]—

is modified according to the present invention, it is thereafter definedas a V “terminal” unit, or simply a V unit. However, for the purposes ofthe present invention, some or all of the primary amine moieties canremain unmodified subject to the restrictions further described hereinbelow. These unmodified primary amine moieties by virtue of theirposition in the backbone chain remain “terminal” units. Likewise, when aprimary amine moiety, located at the end of the main polyamine backbonehaving the structure

—NH₂

is modified according to the present invention, it is thereafter definedas a Z “terminal” unit, or simply a Z unit. This unit can remainunmodified subject to the restrictions further described herein below.

In a similar manner, secondary amine nitrogens comprising the backboneor branching chain once modified are defined as W “backbone” units. Forexample, when a secondary amine moiety, the major constituent of thebackbones and branching chains of the present invention, having thestructure

—[N(H)—R]—

is modified according to the present invention, it is thereafter definedas a W “backbone” unit, or simply a W unit. However, for the purposes ofthe present invention, some or all of the secondary amine moieties canremain unmodified. These unmodified secondary amine moieties by virtueof their position in the backbone chain remain “backbone” units.

In a further similar manner, tertiary amine nitrogens comprising thebackbone or branching chain once modified are further referred to as Y“branching” units. For example, when a tertiary amine moiety, which is achain branch point of either the polyamine backbone or other branchingchains or rings, having the structure

—[N(—)—R]—

wherein (—) indicates a covalent bond, is modified according to thepresent invention, it is thereafter defined as a Y “branching” unit, orsimply a Y unit. However, for the purposes of the present invention,some or all or the tertiary amine moieties can remain unmodified. Theseunmodified tertiary amine moieties by virtue of their position in thebackbone chain remain “branching” units. The R units associated with theV, W and Y unit nitrogens which serve to connect the polyaminenitrogens, are described herein below.

The final modified structure of the polyamines of the present inventioncan be therefore represented by the general formula

V_((n+1))W_(m)Y_(n)Z

for linear polyamine cotton soil release polymers and by the generalformula

V_((n−k+1))W_(m)Y_(n)Y′_(k)Z

for cyclic polyamine cotton soil release polymers. For the case ofpolyamines comprising rings, a Y′ unit of the formula

—[N(R—)—R]—

serves as a branch point for a backbone or branch ring. For every Y′unit there is a Y unit having the formula

—[N(—)—R]—

that will form the connection point of the ring to the main polymerchain or branch. In the unique case where the backbone is a completering, the polyamine backbone has the formula

[H₂N—R]_(n)—[N(H)—R]_(m)—[N(—)—R]_(n)—

therefore comprising no Z terminal unit and having the formula

V_(n−k)W_(m)Y_(n)Y′_(k)

wherein k is the number of ring forming branching units. Preferably thepolyamine backbones of the present invention comprise no rings.

In the case of non-cyclic polyamines, the ratio of the index n to theindex m relates to the relative degree of branching. A fullynon-branched linear modified polyamine according to the presentinvention has the formula

VW_(m)Z

that is, n is equal to 0. The greater the value of n (the lower theratio of m to n), the greater the degree of branching in the molecule.Typically the value for m ranges from a minimum value of 4 to about 400,however larger values of m, especially when the value of the index n isvery low or nearly 0, are also preferred.

Each polyamine nitrogen whether primary, secondary or tertiary, oncemodified according to the present invention, is further defined as beinga member of one of three general classes; simple substituted,quaternized or oxidized. Those polyamine nitrogen units not modified areclassed into V, W, Y, or Z units depending on whether they are primary,secondary or tertiary nitrogens. That is unmodified primary aminenitrogens are V or Z units, unmodified secondary amine nitrogens are Wunits and unmodified tertiary amine nitrogens are Y units for thepurposes of the present invention.

Modified primary amine moieties are defined as V “terminal” units havingone of three forms:

a) simple substituted units having the structure:

N(E₂)—R—

b) quaternized units having the structure:

N(E₃)—R—(X⁻)

wherein X is a suitable counter ion providing charge balance; and

c) oxidized units having the structure:

(—R)E₂)N→O

Modified secondary amine moieties are defined as W “backbone” unitshaving one of three forms:

a) simple substituted units having the structure:

—N(E)—R—

b) quaternized units having the structure:

 —N⁺(E₂)—R—

wherein X is a suitable counter ion providing charge balance; and

c) oxidized units having the structure:

—N(E)(R—)→O

Modified tertiary amine moieties are defined as Y “branching” unitshaving one of three forms:

a) unmodified units having the structure:

(—)₂N—R—,

b) quaternized units having the structure:

(—)₂(E)N⁺—R—,

wherein X is a suitable counter ion providing charge balance; and

c) oxidized units having the structure:

—R—N(—)₂→O,

Certain modified primary amine moieties are defined as Z “terminal”units having one of three forms:

a) simple substituted units having the structure:

—N(E)₂

b) quaternized units having the structure:

—N⁺(E)₃X⁻

wherein X is a suitable counter ion providing charge balance; and

c) oxidized units having the structure:

—R—N(E)₂→O,

When any position on a nitrogen is unsubstituted, or unmodified, it isunderstood that hydrogen will substitute for E. For example, a primaryamine unit comprising one E unit in the form of a hydroxyethyl moiety isa V terminal unit having the formula (HOCH₂CH₂)HN—.

For the purposes of the present invention there are two types of chainterminating units, the V and Z units. The Z “terminal” unit derives froma terminal primary amino moiety of the structure —NH₂. Non-cyclicpolyamine backbones according to the present invention comprise only oneZ unit whereas cyclic polyamines can comprise no Z units. The Z“terminal” unit can be substituted with any of the E units describedfurther herein below, except when the Z unit is modified to form anN-oxide. In the case where the Z unit nitrogen is oxidized to anN-oxide, the nitrogen must be modified and therefore E cannot be ahydrogen.

The polyamines of the present invention comprise backbone R “linking”units that serve to connect the nitrogen atoms of the backbone. R unitscomprise units that for the purposes of the present invention arereferred to as “hydrocarbyl R” units and “oxy R” units. The“hydrocarbyl” R units are C₂-C₁₂ alkylene, C₄-C₁₂ alkenylene, C₃-C₁₂hydroxyalkylene wherein the hydroxyl moiety can take any position on theR unit chain except the carbon atoms directly connected to the polyaminebackbone nitrogens; C₄-C₁₂ dihydroxyalkylene wherein the hydroxylmoieties can occupy any two of the carbon atoms of the R unit chainexcept those carbon atoms directly connected to the polyamine backbonenitrogens; C₈-C₁₂ dialkylarylene which for the a purpose of the presentinvention are arylene moieties having two alkyl substituent groups aspart of the linking chain. For example, a dialkylarylene unit has theformula

although the unit need not be 1,4-substituted, but can also be 1,2 or1,3 substituted C₂-C₁₂ alkylene, preferably ethylene, 1,2-propylene, andmixtures thereof, more preferably ethylene. The “oxy” R units comprise—(R¹O)_(x)R⁵(OR¹)_(x)—,CH₂CH(OR²)CH₂O)_(z)(R¹O)_(y)R¹(OCH₂CH(OR²)CH₂)_(w)—, —CH₂CH(OR²)CH₂—,(R¹O)_(x)R¹—, and mixtures thereof Preferred R units are C₂-C₁₂alkylene, C₃-C₁₂ hydroxyalkylene, C₄-C₁₂ dihydroxyalkylene, C₈-C₁₂dialkylarylene, —(R¹O)_(x)R¹—, —CH₂CH(OR²)CH₂—,—(CH₂CH(OH)CH₂O)_(z)(R¹O)_(y)R¹(OCH₂CH—(OH)CH₂)_(w)—,—(R¹O)_(x)R⁵(OR¹)_(x)—, more preferred R units are C₂-C₁₂ alkylene,C₃-C₁₂ hydroxy-alkylene, C₄-C₁₂ dihydroxyalkylene, —(R¹O)_(x)R¹—,—(R¹O)_(x)R⁵(OR¹)_(x)—,—(CH₂CH(OH)CH₂O)_(z)(R¹O)_(y)R¹(OCH₂CH—(OH)CH₂)_(w)—, and mixturesthereof, even more preferred R units are C₂-C₁₂ alkylene, C₃hydroxyalkylene, and mixtures thereof, most preferred are C₂-C₆alkylene. The most preferred backbones of the present invention compriseat least 50% R units that are ethylene.

R¹ units are C₂-C₆ alkylene, and mixtures thereof, preferably ethylene.

R² is hydrogen, and —(R¹O)_(x)B, preferably hydrogen.

R³ is C₁-C₁₈ alkyl, C₇-C₁₂ arylalkylene, C₇-C₁₂ alkyl substituted aryl,C₆-C₁₂ aryl, and mixtures thereof, preferably C₁-C₁₂ acyl, C₇-C₁₂arylalkylene, more preferably C₁-C₁₂ alkyl, most preferably methyl. R³units serve as part of E units described hereinbelow.

R⁴ is C₁--C₁₂ alkylene, C₄-C₁₂ alkenylene, C₈-C₁₂ arylalkylene, C₆-C₁₀arylene, preferably C₁-C₁₀ alkylene, C₈-C₁₂ arylalkylene, morepreferably C₂-C₈ alkylene, most preferably ethylene or butylene.

R⁵ is C₁-C₁₂ alkylene, C₃-C₁₂ hydroxyalkylene, C₄-C₁₂ dihydroxyalkylene,C₈-C₁₂ dialkylarylene, —C(O)—, —C(O)NHR⁶NHC(O)—, —C(O)(R⁴)_(r)C(O)—,—R¹(OR¹)—, —CH₂CH(OH)CH₂O(R¹O)_(y)R¹OCH₂CH(OH)CH₂—, —C(O)(⁴)_(r)C(O)—,—CH₂CH(OH)CH₂—, R⁵ is preferably ethylene, —C(O)—, —C(O)NHR⁶NHC(O)—,—R¹(OR¹ )—, —CH₂CH(OH)CH₂—, —CH₂CH(OH)CH₂O(R¹O)_(y)R¹OCH₂CH—(OH)CH₂—,more preferably —CH₂CH(OH)CH₂—.

R⁶ is C₂-C₁₂ alkylene or C₆-C₁₂ arylene.

The preferred “oxy” R units are further defined in terms of the R¹, R²,and R⁵ units. Preferred “oxy” R units comprise the preferred R¹, R², andR⁵ units. The preferred cotton soil release agents of the presentinvention comprise at least 50% R¹ units that are ethylene. PreferredR¹, R², and R⁵ units are combined with the “oxy” R units to yield thepreferred “oxy” R units in the following manner.

i) Substituting more preferred R⁵ into —(CH₂CH₂O)_(x)R⁵(OCH₂CH₂)_(x)—yields —(CH₂CH₂O)_(x)CH₂CHOHCH₂(OCH₂CH₂)_(x)—.

ii) Substituting preferred R¹ and R² into—(CH₂CH(OR²)CH₂O)_(z)—(R¹O)_(y)R¹O(CH₂CH(OR²)CH₂)_(w)— yields—(CH₂CH(OH)CH₂O)_(z)—(CH₂CH₂O)_(y)CH₂CH₂O(CH₂CH(OH)CH₂)_(w)—.

iii) Substituting preferred R² into —CH₂CH(OR²)CH₂— yields—CH₂CH(OH)CH₂—.

E units are selected from the group consisting of hydrogen, C₁-C₂₂alkyl, C₃-C₂₂ alkenyl, C₇-C₂₂ arylalkyl, C₂-C₂₂ hydroxyalkyl,—(CH₂)_(p)CO₂M, —(CH₂)_(q)SO₃M, —CH(CH₂CO₂M)CO₂M, —(CH₂)_(p)PO₃M,—(R¹O)_(m)B, —C(O)R³, preferably hydrogen, C₂-C₂₂ hydroxyalkylene,benzyl, C₁-C₂₂ alkylene, —(R¹O)_(m)B, —C(O)R³, —(CH₂)_(p)CO₂M,—(CH₂)_(q)SO₃M, —CH(CH₂CO₂M)CO₂M, more preferably C₁-C₂₂ alkylene,—(R¹O)_(x)B, —C(O)R³, —(CH₂)_(p)CO₂M, —(CH₂)_(q)SO₃M, —CH(CH₂CO₂M)CO₂M,most preferably C₁-C₂₂ alkylene, —(R¹O)_(x)B, and —C(O)R³. When nomodification or substitution is made on a nitrogen then hydrogen atomwill remain as the moiety representing E.

E units do not comprise hydrogen atom when the V, W or Z units areoxidized, that is the nitrogens are N-oxides. For example, the backbonechain or branching chains do not comprise units of the followingstructures:

(—)₀₋₁(R)₀₋₁(H)₁₋₂N→O

Additionally, E units do not comprise carbonyl moieties directly bondedto a nitrogen atom when the V, W or Z units are oxidized, that is, thenitrogens are N-oxides. According to the present invention, the E unit—C(O)R³ moiety is not bonded to an N-oxide modified nitrogen, that is,there are no N-oxide amides having the structures

R³—C(O)N(E)₀₋₁(—)₀₋₁→O

or combinations thereof.

B is hydrogen, C₁-C₆ alkyl, —(CH₂)_(q)SO₃M, —(CH₂)_(p)CO₂M,—(CH₂)_(q)—(CHSO₃M)CH₂SO₃M, —(CH₂)_(q)(CHSO₂M)CH₂SO₃M, —(CH₂)_(p)PO₃M,—PO₃M, preferably hydrogen, —(CH₂)_(q)SO₃M, —(CH₂)_(q)(CHSO₃M)CH₂SO₃M,—(CH₂)_(q)—(CHSO₂M)CH₂SO₃M, more preferably hydrogen or —(CH₂)_(q)SO₃M.

M is hydrogen or a water soluble cation in sufficient amount to satisfycharge balance. For example, a sodium cation equally satisfies—(CH₂)_(p)CO₂M, and —(CH₂)_(q)SO₃M, thereby resulting in—(CH₂)_(p)CO₂Na, and —(CH₂)_(q)SO₃Na moieties. More than one monovalentcation, (sodium, potassium, etc.) can be combined to satisfy therequired chemical charge balance. However, more than one anionic groupmay be charge balanced by a divalent cation, or more than onemono-valent cation may be necessary to satisfy the charge requirementsof a poly-anionic radical. For example, a —(CH₂)_(p)PO₃M moietysubstituted with sodium atoms has the formula —(CH₂)_(p)PO₃Na₃. Divalentcations such as calcium (Ca²⁺) or magnesium (Mg²⁺) may be substitutedfor or combined with other suitable mono-valent water soluble cations.Preferred cations are sodium and potassium, more preferred is sodium.

X is a water soluble anion such as chlorine (Cl⁻), bromine (Br⁻) andiodine (I⁻) or X can be any negatively charged radical such as sulfate(SO₄ ²⁻) and methosulfate (CH₃SO₃ ⁻).

The formula indices have the following values: p has the value from 1 to6, q has the value from 0 to 6; r has the value 0 or 1; w has the value0 or 1, x has the value from 1 to 100; y has the value from 0 to 100; zhas the value 0 or 1; k is less than or equal to the value of n; m hasthe value from 4 to about 400, n has the value from 0 to about 200; m+nhas the value of at least 5.

The preferred polyamine cationic polymers of the present inventioncomprise polyamine backbones wherein less than about 50% of the R groupscomprise “oxy” R units, preferably less than about 20%, more preferablyless than 5%, most preferably the R units comprise no “oxy” R units.

The most preferred polyamine cationic polymers which comprise no “oxy” Runits comprise polyamine backbones wherein less than 50% of the R groupscomprise more than 3 carbon atoms. For example, ethylene, 1,2-propylene,and 1,3-propylene comprise 3 or less carbon atoms and are the preferred“hydrocarbyl” R units. That is when backbone R units are C₂-C₁₂alkylene, preferred is C₂-C₃ alkylene, most preferred is ethylene.

The polyamine cationic polymers of the present invention comprisemodified homogeneous and non-homogeneous polyamine backbones, wherein100% or less of the —NH units are modified. For the purpose of thepresent invention the term “homogeneous polyamine backbone” is definedas a polyamine backbone having R units that are the same (i.e., allethylene). However, this sameness definition does not exclude polyaminesthat comprise other extraneous units comprising the polymer backbonewhich are present due to an artifact of the chosen method of chemicalsynthesis. For example, it is known to those skilled in the art thatethanolamine may be used as an “initiator” in the synthesis ofpolyethyleneimines, therefore a sample of polyethyleneimine thatcomprises one hydroxyethyl moiety resulting from the polymerization“initiator” would be considered to comprise a homogeneous polyaminebackbone for the purposes of the present invention. A polyamine backbonecomprising all ethylene R units wherein no branching Y units are presentis a homogeneous backbone. A polyamine backbone comprising all ethyleneR units is a homogeneous backbone regardless of the degree of branchingor the number of cyclic branches present.

For the purposes of the present invention the term “non-homogeneouspolymer backbone” refers to polyamine backbones that are a composite ofvarious R unit lengths and R unit types. For example, a non-homogeneousbackbone comprises R units that are a mixture of ethylene and1,2-propylene units. For the purposes of the present invention a mixtureof “hydrocarbyl” and “oxy” R units is not necessary to provide anon-homogeneous backbone. The proper manipulation of these “R unit chainlengths” provides the formulator with the ability to modify thesolubility and fabric substantivity of the polyamine cationic polymersof the present invention.

One type of preferred polyamine cationic polymers of the presentinvention comprise homogeneous polyamine backbones that are totally orpartially substituted by polyethyleneoxy moieties, totally or partiallyquaternized amines, nitrogens totally or partially oxidized to N-oxides,and mixtures thereof. However, not all backbone amine nitrogens must bemodified in the same manner, the choice of modification being left tothe specific needs of the formulator. The degree of ethoxylation is alsodetermined by the specific requirements of the formulator.

The preferred polyamines that comprise the backbone of the compounds ofthe present invention are generally polyalkyleneamines (PAA's),polyalkyleneimines (PAI's), preferably polyethyleneamine (PEA's),polyethyleneimines (PEI's), or PEA's or PEI's connected by moietieshaving longer R units than the parent PAA's, PAI's, PEA's or PEI's. Acommon polyalkyleneamine (PAA) is tetrabutylenepentamine. PEA's areobtained by reactions involving ammonia and ethylene dichloride,followed by fractional distillation. The common PEA's obtained aretriethylenetetramine (TETA) and teraethylenepentamine (TEPA). Above thepentamnines, i.e., the hexamaines, heptamines, octamines and possiblynonamines, the cogenerically derived mixture does not appear to separateby distillation and can include other materials such as cyclic aminesand particularly piperazines. There can also be present cyclic amineswith side chains in which nitrogen atoms appear. See U.S. Pat. No.2,792,372, Dickinson, issued May 14, 1957, which describes thepreparation of PEA's.

Preferred amine polymer backbones comprise R units that are C₂ alkylene(ethylene) units, also known as polyethylenimines (PEI's). PreferredPEI's have at least moderate branching, that is the ratio of m to n isless than 4:1, however PEI's having a ratio of m to n of about 2:1 aremost preferred. Preferred backbones, prior to modification have thegeneral formula:

[H₂NCH₂CH₂]_(n)—[N(H)CH₂CH₂]_(m)—N(—)CH₂CH₂]_(n)NH₂

wherein (—), m, and n are the same as defined herein above. PreferredPEI's, prior to modification, will have a molecular weight greater thanabout 200 daltons.

The relative proportions of primary, secondary and tertiary amine unitsin the polyamine backbone, especially in the case of PEI's, will vary,depending on the manner of preparation. Each hydrogen atom attached toeach nitrogen atom of the polyamine backbone chain represents apotential site for subsequent substitution, quaternization or oxidation.

These polyamines can be prepared, for example, by polymerizingethyleneimine in the presence of a catalyst such as carbon dioxide,sodium bisulfite, sulfuric acid, hydrogen peroxide, hydrochloric acid,acetic acid, etc. Specific methods for preparing these polyaminebackbones are disclosed in U.S. Pat. No. 2,182,306, Ulrich et al.,issued Dec. 5, 1939; U.S. Pat. No.3,033,746, Mayle et al., issued May 8,1962; U.S. Pat. No. 2,208,095, Esselmann et al., issued Jul. 16, 1940;U.S. Pat. No. 2,806,839, Crowther, issued Sep. 17, 1957; and U.S. Pat.No. 2,553,696, Wilson, issued May 21, 1951; all herein incorporated byreference.

Examples of modified polyamine cationic polymers of the presentinvention comprising PEI's, are illustrated in Formulas I-II:

Formula I depicts a polyamine cationic polymer comprising a PEI backbonewherein all substitutable nitrogens are modified by replacement ofhydrogen with a polyoxyalkyleneoxy unit, —(CH₂CH₂O)₇H, having theformula

This is an example of a polyamine cationic polymer that is fullymodified by one type of moiety.

Formula II depicts a polyamine cationic polymer comprising a PEIbackbone wherein all substitutable primary amine nitrogens are modifiedby replacement of hydrogen with a polyoxyalkyleneoxy unit, —(CH₂CH₂O)₇H,the molecule is then modified by subsequent oxidation of all oxidizableprimary and secondary nitrogens to N-oxides, said polyamine cationicpolymer having the formula

Another related polyamine cationic polymer comprises a PEI backbonewherein all backbone hydrogen atoms are substituted and some backboneamine units are quaternized. The substituents are polyoxyalkyleneoxyunits, —(CH₂CH₂O)₇H, or methyl groups. Yet another related polyaminecationic polymer comprises a PEI backbone wherein the backbone nitrogensare modified by substitution (i.e. by —(CH₂CH₂O)₇H or methyl),quaternized, oxidized to N-oxides or combinations thereof.

These polyamine cationic polymers, in addition to providing improvedsoftening, can operate as cotton soil release agents, when used in aneffective amount, e.g., from about 0.001% to about 10%, preferably fromabout 0.01% to about 5%, and more preferably from about 0.1% to about1%.

Preferred cationic polymeric materials, as discussed hereinbefore, arethe cationic polysaccharides, especially cationic galactomannam gums(such as guar gum) and cationic derivatives. These materials arecommercially available and relatively inexpensive. They have goodcompatibility with cationic surfactants and allow stable, highlyeffective softening compositions according to the invention to beprepared. Such polymeric materials are preferably used at a level offrom 0.03% to 0.5% of the composition.

Of course, mixtures of any of the above described cationic polymers canbe employed, and the selection of individual polymers or of particularmixtures can be used to control the physical properties of thecompositions such as their viscosity and the stability of the aqueousdispersions.

These cationic polymers are usually effective at levels of from about0.001% to about 10% by weight of the compositions depending upon thebenefit sought. The molecular weights are in the range of from about 500to about 1,000,000, preferably from about 1,000 to about 500,000, morepreferably from about 1,000 to about 250,000.

In order to be effective, the cationic polymers herein should be, atleast to the level disclosed herein, in the continuous aqueous phase. Inorder to ensure that the polymers are in the continuous aqueous phase,they are preferably added at the very end of the process for making thecompositions. The fabric softener actives are normally present in theform of vesicles. After the vesicles have formed, and while thetemperature is less than about 85° F., the polymers are added.

Optional Viscosity/Dispersibility Modifiers

As stated before, relatively concentrated compositions of theunsaturated DEQA can be prepared that are stable without the addition ofconcentration aids. However, the compositions of the present inventionusually benefit from the presence of organic and/or inorganicconcentration aids at higher concentrations and/or to meet higherstability standards depending on the other ingredients. Theseconcentration aids which typically can be viscosity modifiers can helpensure stability under extreme conditions when particular softeneractive levels in relation to IV are present.

This relationship between IV and the concentration where concentrationaids are needed in a typical aqueous liquid fabric softener compositioncontaining perfume can be defined, at least approximately, by thefollowing equation (for IVs of from greater than about 25 to less thanabout 100): Concentration of Softener Active (Wt. %)=4.85+0.838(IV)−0.00756 (IV)² (where R²=0.99). Above these softener active levels,concentration aids are usually beneficial. These numbers are onlyapproximations and if other variables of the formulation change, such assolvent, other ingredients, fatty acids, etc., concentration aids can berequired for slightly lower concentrations or not required for slightlyhigher concentrations. For non-perfume or low level perfume compositions(“unscented” compositions), higher concentrations are possible at givenIV levels. If the formulation separates, concentration aids can be addedto achieve the desired criteria.

I. Surfactant Concentration Aids

The optional surfactant concentration aids are typically selected fromthe group consisting of (1) single long chain alkyl cationicsurfactants; (2) nonionic surfactants; (3) amine oxides; (4) fattyacids; or (5) mixtures thereof. The levels of these aids are describedbelow.

(1) The Single-Lone-Chain Alkyl Cationic Surfactant

The mono-long-chain-alkyl (water-soluble) cationic surfactants:

I. in solid compositions are at a level of from 0% to about 15%,preferably from about 3% to about 15%, more preferably from about 5% toabout 15%, and

II. in liquid compositions are at a level of from 0% to about 15%,preferably from about 0.5% to about 10%, the total single-long-chaincationic surfactant being at least at an effective level.

Such mono-long-chain-alkyl cationic surfactants useful in the presentinvention are, preferably, quaternary ammonium salts of the generalformula:

[R²N⁺R₃]X⁻

wherein the R² group is C₁₀-C₂₂ hydrocarbon group, preferably C₁₂-C₁₈alkyl group or the corresponding ester linkage interrupted group with ashort alkylene (C₁-C₄) group between the ester linkage and the N, andhaving a similar hydrocarbon group, e.g., a fatty acid ester of choline,preferably C₁₂-C₁₄ (coco) choline ester andlor C₁₆-C₁₈ tallow cholineester at from about 0.1% to about 20% by weight of the softener active.Each R is a C₁-C₄ alkyl or substituted (e.g., hydroxy) alkyl, orhydrogen, preferably methyl, and the counterion X⁻ is a softenercompatible anion, for example, chloride, bromide, methyl sulfate, etc.

The ranges above represent the amount of the single-long-chain-alkylcationic surfactant which is added to the composition of the presentinvention. The ranges do not include the amount of monoester which isalready present in component (A), the diester quaternary ammoniumcompound, the total present being at least at an effective level.

The long chain group R², of the single-long-chain-alkyl cationicsurfactant, typically contains an alkylene group having from about 10 toabout 22 carbon atoms, preferably from about 12 to about 16 carbon atomsfor solid compositions, and preferably from about 12 to about 18 carbonatoms for liquid compositions. This R² group can be attached to thecationic nitrogen atom through a group containing one, or more, ester,amide, ether, amine, etc., preferably ester, linking groups which can bedesirable for increased hydrophilicity, biodegradability, etc. Suchlinking groups are preferably within about three carbon atoms of thenitrogen atom. Suitable biodegradable single-long-chain alkyl cationicsurfactants containing an ester linkage in the long chain are describedin U.S. Pat. No. 4,840,738, Hardy and Walley, issued Jun. 20, 1989, saidpatent being incorporated herein by reference.

If the corresponding, non-quaternary amines are used, any acid(preferably a mineral or polycarboxylic acid) which is added to keep theester groups stable will also keep the amine protonated in thecompositions and preferably during the rinse so that the amine has acationic group. The composition is buffered (pH from about 2 to about 5,preferably from about 2 to about 4) to maintain an appropriate,effective charge density in the aqueous liquid concentrate product andupon further dilution e.g., to form a less concentrated product and/orupon addition to the rinse cycle of a laundry process.

It will be understood that the main function of the water-solublecationic surfactant is to lower the viscosity and/or increase thedispersibility of the diester softener and it is not, therefore,essential that the cationic surfactant itself have substantial softeningproperties, although this may be the case. Also, surfactants having onlya single long alkyl chain, presumably because they have greatersolubility in water, can protect the diester softener from interactingwith anionic surfactants and/or detergent builders that are carried overinto the rinse. However, the cationic polymers of this invention willserve this function, so it is preferable to keep the level of singlelong chain cationic materials low, preferably less than about 10%, morepreferably less than about 7%, to minimize such extraneous materials.

Other cationic materials with ring structures such as alkyl imidazoline,imidazolinium, pyridine, and pyridinium salts having a single C₁₂-C₃₀alkyl chain can also be used. Very low pH is required to stabilize,e.g., imidazoline ring structures.

(2) Nonionic Surfactant (Alkoxylated Materials)

Suitable nonionic surfactants to serve as the viscosity/dispersibilitymodifier include addition products of ethylene oxide and, optionally,propylene oxide, with fatty alcohols, fatty acids, fatty amines, etc.

Any of the alkoxylated materials of the particular type describedhereinafter can be used as the nonionic surfactant. In general terms,the nonionics herein, when used alone, I. in solid compositions are at alevel of from about 5% to about 20%, preferably from about 8% to about15%, and II. in liquid compositions are at a level of from 0% to about5%, preferably from about 0.1% to about 5%, more preferably from about0.2% to about 3%. Suitable compounds are substantially water-solublesurfactants of the general formula:

—R²—Y—(C₂H₄O)_(z)—C₂H₄OH

wherein R² for both solid and liquid compositions is selected from thegroup consisting of primary, secondary and branched chain alkyl and/oracyl hydrocarbyl groups; primary, secondary and branched chain alkenylhydrocarbyl groups; and primary, secondary and branched chain alkyl- andalkenyl-substituted phenolic hydrocarbyl groups; said hydrocarbyl groupshaving a hydrocarbyl chain length of from about 8 to about 20,preferably from about 10 to about 18 carbon atoms. More preferably thehydrocarbyl chain length for liquid compositions is from about 16 toabout 18 carbon atoms and for solid compositions from about 10 to about14 carbon atoms. In the general formula for the ethoxylated nonionicsurfactants herein, Y is typically —O—, —C(O)O—, —C(O)N(R)—, or—C(O)N(R)R—, in which R², and R, when present, have the meanings givenhereinbefore, and/or R can be hydrogen, and z is at least about 8,preferably at least about 10-11. Performance and, usually, stability ofthe softener composition decrease when fewer ethoxylate groups arepresent.

The nonionic surfactants herein are characterized by an HLB(hydrophilic-lipophilic balance) of from about 7 to about 20, preferablyfrom about 8 to about 15. Of course, by defining R² and the number ofethoxylate groups, the HLB of the surfactant is, in general, determined.However, it is to be noted that the nonionic ethoxylated surfactantsuseful herein, for concentrated liquid compositions, contain relativelylong chain R² groups and are relatively highly ethoxylated. Whileshorter alkyl chain surfactants having short ethoxylated groups maypossess the requisite HLB, they are not as effective herein.

Nonionic surfactants as the viscosity/dispersibility modifiers arepreferred over the other modifiers disclosed herein for compositionswith higher levels of perfume.

Examples of nonionic surfactants follow. The nonionic surfactants ofthis invention are not limited to these examples. In the examples, theinteger defines the number of ethoxyl (EO) groups in the molecule.

a. Straight-Chain, Primary Alcohol Alkoxylates

The deca-, undeca-, dodeca-, tetradeca-, and pentadecaethoxylates ofn-hexadecanol, and n-octadecanol having an HLB within the range recitedherein are useful viscosity/dispersibility modifiers in the context ofthis invention. Exemplary ethoxylated primary alcohols useful herein asthe viscosityldispersibility modifiers of the compositions aren-C₁₈EO(10); and n-C₁₀EO(11). The ethoxylates of mixed natural orsynthetic alcohols in the “tallow” chain length range are also usefulherein. Specific examples of such materials includetallowalcohol-EO(11), tallowalcohol-EO(18), and tallowalcohol-EO(25).

b. Straight-Chain, Secondary Alcohol Alkoxylates

The deca-, undeca-, dodeca-, tetradeca-, pentadeca-, octadeca-, andnonadeca-ethoxylates of 3-hexadecanol, 2-octadecanol, 4-eicosanol, and5-eicosanol having and BLB within the range recited herein are usefulviscosity/dispersibility modifiers in the context of this invention.Exemplary ethoxylated secondary alcohols useful herein as theviscosity/dispersibility modifiers of the compositions are: 2-C₁₆EO(11);2-C₂₀EO(11); and 2-C₁₆EO(14).

c. Alkyl Phenol Alkoxylates

As in the case of the alcohol alkoxylates, the hexa- throughoctadeca-ethoxylates of alkylated phenols, particularly monohydricalkylphenols, having an HLB within the range recited herein are usefullas the viscosity/dispersibility modifiers of the instant compositions.The hexa- through octadeca-ethoxylates of p-tridecyl-phenol,m-pentadecylphenol, and the like, are useful herein. Exemplaryethoxylated alkylphenols useful as the viscosity/dispersibilitymodifiers of the mixtures herein are: p-tridecylphenol EO(11) andp-pentadecylphenol EO(18).

As used herein and as generally recognized in the art, a phenylene groupin the nonionic formula is the equivalent of an alkylene groupcontaining from 2 to 4 carbon atoms. For present purposes, nonionicscontaining a phenylene group are considered to contain an equivalentnumber of carbon atoms calculated as the sum of the carbon atoms in thealkyl group plus about 3.3 carbon atoms for each phenylene group.

d. Olefinic Alkoxylates

The alkenyl alcohols, both primary and secondary, and alkenyl phenolscorresponding to those disclosed immediately hereinabove can beethoxylated to an HLB within the range recited herein and used as theviscosity/dispersibility modifiers of the instant compositions.

e. Branched Chain Alkoxylates

Branched chain primary and secondary alcohols which are available fromthe well-known “OXO” process can be ethoxylated and employed as theviscosity/dispersibility modifiers of compositions herein.

The above ethoxylated nonionic surfactants are useful in the presentcompositions alone or in combination, and the term “nonionic surfactant”encompasses mixed nonionic surface active agents.

(3) Amine Oxides

Suitable amine oxides include those with one alkyl or hydroxyalkylmoiety of about 8 to about 28 carbon atoms, preferably from about 8 toabout 16 carbon atoms, and two alkyl moieties selected from the groupconsisting of alkyl groups and hydroxyalkyl groups with about 1 to about3 carbon atoms.

The amine oxides:

I. in solid compositions are at a level of from 0% to about 15%,preferably from about 3% to about 15%; and

II. in liquid compositions are at a level of from 0% to about 5%,preferably from about 0.25% to about 2%, the total amine oxide presentat least at an effective level.

Examples include dimethyloctylamine oxide, diethyldecylamine oxide,bis-(2-hydroxyethyl)dodecylamine oxide, dimethyldodecylamine oxide,dipropyltetradecylamine oxide, methylethylhexadecylamine oxide,dimethyl-2-hydroxyoctadecylamine oxide, and coconut fatty alkyldimethylamine oxide.

(4) Fatty Acids

Suitable fatty acids include those containing from about 12 to about 25,preferably from about 13 to about 22, more preferably from about 16 toabout 20, total carbon atoms, with the fatty moiety containing fromabout 10 to about 22, preferably from about 10 to about 18, morepreferably from about 10 to about 14 (mid cut), carbon atoms. Theshorter moiety contains from about 1 to about 4, preferably from about 1to about 2 carbon atoms.

Fatty acids are present at the levels outlined above for amine oxides.Fatty acids are preferred concentration aids for those compositionswhich require a concentration aid and contain perfume.

II. Electrolyte Concentration Aids

Inorganic viscosity control agents which can also act like or augmentthe effect of the surfactant concentration aids, include water-soluble,ionizable salts which can also optionally be incorporated into thecompositions of the present invention. A wide variety of ionizable saltscan be used. Examples of suitable salts are the halides of the Group IAand IIA metals of the Periodic Table of the Elements, e.g., calciumchloride, magnesium chloride, sodium chloride, potassium bromide, andlithium chloride. The ionizable salts are particularly useful during theprocess of mixing the ingredients to make the compositions herein, andlater to obtain the desired viscosity. The amount of ionizable saltsused depends on the amount of active ingredients used in thecompositions and can be adjusted according to the desires of theformulator. Typical levels of salts used to control the compositionviscosity are from about 20 to about 20,000 parts per million (ppm),preferably from about 20 to about 11,000 ppm, by weight of thecomposition.

Alkylene polyammonium salts can be incorporated into the composition togive viscosity control in addition to or in place of the water-soluble,ionizable salts above. In addition, these agents can act as scavengers,forming ion pairs with anionic detergent carried over from the mainwash, in the rinse, and on the fabrics, and can improve softnessperformance. These agents can stabilize the viscosity over a broaderrange of temperature, especially at low temperatures, compared to theinorganic electrolytes.

Specific examples of alkylene polyammonium salts include 1-lysinemonohydrochloride and 1,5-diammonium 2-methyl pentane dihydrochloride.

(C) Stabilizers

Stabilizers can be present in the compositions of the present invention.The term “stabilizer,” as used herein, includes antioxidants andreductive agents. These agents are present at a level of from 0% toabout 2%, preferably from about 0.01% to about 0.2%, more preferablyfrom about 0.035% to about 0.1% for antioxidants, and more preferablyfrom about 0.01% to about 0.2% for reductive agents. These assure goododor stability under long term storage conditions for the compositionsand compounds stored in molten form. Use of antioxidants and reductiveagent stabilizers is especially critical for unscented or low scentproducts (no or low perfume).

Examples of antioxidants that can be added to the compositions of thisinvention include a mixture of ascorbic acid, ascorbic palmitate, propylgailate, available from Eastman Chemical Products, Inc., under the tradenames Tenox® PG and Tenox S-1; a mixture of BHT (butylatedhydroxytoluene), BHA (butylated hydroxyanisole), propyl gallate, andcitric acid, available from Eastman Chemical Products, Inc., under thetrade name Tenox-6; butylated hydroxytoluene, available from UOP ProcessDivision under the trade name Sustane® BHT; tertiary butylhydroquinone,Eastman Chemical Products, Inc., as Tenox TBHQ; natural tocopherols,Eastman Chemical Products, Inc., as Tenox GT-1/GT-2; and butylatedhydroxyanisole, Eastman Chemical Products, Inc., as BHA; long chainesters (C₈-C₂₂) of gallic acid, e.g., dodecyl gallate; Irganox® 1010;Irganox® 1035; Irganox® B 1171; Irganox® 1425; Irganox® 3114; Irganox®3125; and mixtures thereof; preferably Irganox® 3125, Irganox® 1425,Irganox® 3114, and mixtures thereof; more preferably Irganox® 3125 aloneor mixed with citric acid and/or other chelators such as isopropylcitrate, Dequest® 2010, available from Monsanto with a chemical name of1-hydroxyethylidene-1, 1-diphosphonic acid (etidronic acid), and TironR,available from Kodak with a chemical name of4,5-dihydroxy-m-benzene-sulfonic acid/sodium salt, and DTPAR, availablefrom Aldrich with a chemical name of diethylenetriaminepentaaceticacid.. The chemical names and CAS numbers for some of the abovestabilizers are listed in Table II below.

TABLE II Chemical Name used in Code Antioxidant CAS No. of FederalRegulations Irganox ® 1010 6683-19-8 Tetrakis [methylene(3,5-di-tert-butyl-4 hydroxyhydrocinnamate)] methane Irganox ® 1035 41484-35-9Thiodiethylene bis(3,5-di-tert- butyl-4-hydroxyhydrocinnamate Irganox ®1098 23128-74-7 N,N′-Hexamethylene bis(3,5-di-tert-butyl-4-hydroxyhydrocin- nammamide Irganox ® B 1171 31570-04-4 1:1Blend of Irganox ® 1098 23128-74-7 and Irgafos ® 168 Irganox ® 142565140-91-2 Calcium bis[monoethyl(3,5-di- tert-butyl-4-hydroxybenzyl)phosphonate] Irganox ® 3114 27676-62-6 1,3,5-Tris(3,5-di-tert-butyl-4-hydroxybenzyl)-s-triazine- 2,4,6-(1H, 3H, 5H)trione Irganox ® 312534137-09-2 3,5-Di-tert-butyl-4-hydroxy- hydrocinnamic acid triester with1,3,5-tris(2-hydroxyethyl)- S-triazine-2,4,6-(1H, 3H, 5H)- trioneIrgafos ® 168 31570-04-4 Tris(2,4-di-tert-butyl- phenyl)phosphite

Examples of reductive agents include sodium borohydride, hypophosphorousacid, Irgafos® 168, and mixtures thereof

(D) Liquid Carrier

The liquid carrier employed in the instant compositions is preferably atleast primarily water due to its low cost relative availability, safety,and environmental compatibility. The level of water in the liquidcarrier is at least about 50%, preferably at least about 60%, by weightof the carrier. The level of liquid carrier is less than about 70,preferably less than about 65, more preferably less than about 50.Mixtures of water and low molecular weight, e.g., <100, organic solvent,e.g., lower alcohol such as ethanol, propanol, isopropanol or butanolare useful as the carrier liquid. Low molecular weight alcohols includemonohydric, dihydric (glycol, etc.) trihydric (glycerol, etc.), andhigher polyhydric (polyols) alcohols.

(E) Optional Ingredients (1) Optional Soil Release Agent

Optionally, the compositions herein contain from 0% to about 10%,preferably from about 0.1% to about 5%, more preferably from about 0.1%to about 2%, of a soil release agent. Preferably, such a soil releaseagent is a polymer. Polymeric soil release agents useful in the presentinvention include copolymeric blocks of terephthalate and polyethyleneoxide or polypropylene oxide, and the like. U.S. Pat. No. 4,956,447,Gosselink/Hardy/Trinh, issued Sept. 11, 1990, discloses specificpreferred soil release agents comprising cationic functionalities, saidpatent being incorporated herein by reference.

A preferred soil release agent is a copolymer having blocks ofterephthalate and polyethylene oxide. More specifically, these polymersare comprised of repeating units of ethylene and/or propyleneterephthalate and polyethylene oxide terephthalate at a molar ratio ofethylene terephthalate units to polyethylene oxide terephthalate unitsof from about 25:75 to about 35:65, said polyethylene oxideterephthalate containing polyethylene oxide blocks having molecularweights of from about 300 to about 2000. The molecular weight of thispolymeric soil release agent is in the range of from about 5,000 toabout 55,000.

Another preferred polymeric soil release agent is a crystallizablepolyester with repeat units of ethylene terephthalate units containingfrom about 10% to about 15% by weight of ethylene terephthalate unitstogether with from about 10% to about 50% by weight of polyoxyethyleneterephthalate units, derived from a polyoxyethylene glycol of averagemolecular weight of from about 300 to about 6,000, and the molar ratioof ethylene terephthalate units to polyoxyethylene terephthalate unitsin the crystallizable polymeric compound is between 2:1 and 6:1.Examples of this polymer include the comnmercially available materialsZelcon® 4780 (from DuPont) and Milease® T (from ICI).

Highly preferred soil release agents are polymers of the generic formula(I):

X—(OCH₂CH₂)_(n)(O—(O)C—R¹—C(O)—OR²)_(u)(O—(O)C—R¹—C(O)—O)(CH₂CH₂O—)_(n)—X  (I)

in which X can be any suitable capping group, with each X being selectedfrom the group consisting of H, and alkyl or acyl groups containing fromabout 1 to about 4 carbon atoms, preferably methyl. n is selected forwater solubility and generally is from about 6 to about 113, preferablyfrom about 20 to about 50. u is critical to formulation in a liquidcomposition having a relatively high ionic strength. There should bevery little material in which u is greater than 10. Furthermore, thereshould be at least 20%, preferably at least 40%, of material in which uranges from about 3 to about 5.

The R¹ moieties are essentially 1,4-phenylene moieties. As used herein,the term “the R¹ moieties are essentially 1,4-phenylene moieties” refersto compounds where the R¹ moieties consist entirely of 1,4-phenylenemoieties, or are partially substituted with other arylene or alkarylenemoieties, alkylene moieties, alkenylene moieties, or mixtures thereofArylene and alkarylene moieties which can be partially substituted for1,4-phenylene include 1,3-phenylene, 1,2-phenylene, 1,8-naphthylene,1,4-naphthylene, 2,2-biphenylene, 4,4-biphenylene and mixtures thereof.Alkylene and alkenylene moieties which can be partially substitutedinclude ethylene, 1,2-propylene, 1,4-butylene, 1,5-pentylene,1,6-hexamethylene, 1,7-heptamethylene, 1,8-octamethylene,1,4-cyclohexylene, and mixtures thereof

For the R¹ moieties, the degree of partial substitution with moietiesother than 1,4-phenylene should be such that the soil release propertiesof the compound are not adversely affected to any great extent.Generally, the degree of partial substitution which can be toleratedwill depend upon the backbone length of the compound, i.e., longerbackbones can have greater partial substitution for 1,4-phenylenemoieties. Usually, compounds where the RI comprise from about 50% toabout 100% 1,4-phenylene moieties (from 0 to about 50% moieties otherthan 1,4-phenylene) have adequate soil release activity. For example,polyesters made according to the present invention with a 40:60 moleratio of isophthalic (1,3-phenylene) to terephthalic (1,4-phenylene)acid have adequate soil release activity. However, because mostpolyesters used in fiber making comprise ethylene terephthalate units,it is usually desirable to minimize the degree of partial substitutionwith moieties other than 1,4-phenylene for best soil release activity.Preferably, the R¹ moieties consist entirely of (i.e., comprise 100%)1,4-phenylene moieties, i.e., each R¹ moiety is 1,4-phenylene.

For the R² moieties, suitable ethylene or substituted ethylene moietiesinclude ethylene, 1,2-propylene, 1,2-butylene, 1,2-hexylene,3-methoxy-1,2-propylene and mixtures thereof Preferably, the R² moietiesare essentially ethylene moieties, 1,2-propylene moieties or mixturethereof. Inclusion of a greater percentage of ethylene moieties tends toimprove the soil release activity of compounds. Inclusion of a greaterpercentage of 1,2-propylene moieties tends to improve the watersolubility of the compounds.

Therefore, the use of 1,2-propylene moieties or a similar branchedequivalent is desirable for incorporation of any substantial part of thesoil release component in the liquid fabric softener compositions.Preferably, from about 75% to about 100%, more preferably from about 90%to about 100%, of the R² moieties are 1,2-propylene moieties.

The value for each n is at least about 6, and preferably is at leastabout 10. The value for each n usually ranges from about 12 to about113. Typically, the value for each n is in the range of from about 12 toabout 43.

A more complete disclosure of these highly preferred soil release agentsis contained in European Pat. Application 185,427, Gosselink, publishedJun. 25, 1986, incorporated herein by reference.

(2) Optional Bacteriocides

Examples of bacteriocides that can be used in the compositions of thisinvention are parabens, especially methyl, glutaraldehyde, formaldehyde,2-bromo-2-nitropropane-1,3-diol sold by Inolex Chemicals under the tradename Bronopol®, and a mixture of 5-chloro-2-methyl4-isothiazoline-3-oneand 2-methyl-4-isothiazo-line-3-one sold by Rohm and Haas Company underthe trade name Kathon® CG/ICP. Typical levels of bacteriocides used inthe present compositions are from about 1 to about 2,000 ppm by weightof the composition, depending on the type of bacteriocide selected.Methyl paraben is especially effective for mold growth in aqueous fabricsoftening compositions with under 10% by weight of the diester compound.

(3) Other Optional Ingredients

The present invention can include other optional componentsconventionally used in textile treatment compositions, for example,colorants, perfumes, preservatives, optical brighteners, opacifiers,fabric conditioning agents, surfactants, stabilizers such as guar gumand polyethylene glycol, anti-shrinkage agents, anti-wrinkle agents,fabric crisping agents, spotting agents, germicides, fungicides,anti-corrosion agents, antifoam agents, enzymes such as cellulases,proteases, and the like.

An optional additional softening agent of the present invention is anonionic fabric softener material. Typically, such nonionic fabricsoftener materials have an HLB of from about 2 to about 9, moretypically from about 3 to about 7. Such nonionic fabric softenermaterials tend to be readily dispersed either by themselves, or whencombined with other materials such as single-long-chain alkyl cationicsurfactant described in detail hereinbefore. Dispersibility can beimproved by using more single-long-chain alkyl cationic surfactant,mixture with other materials as set forth hereinafter, use of hotterwater, and/or more agitation. In general, the materials selected shouldbe relatively crystalline, higher melting, (e.g., >˜50° C.) andrelatively water-insoluble.

The level of optional nonionic softener in the solid composition istypically from about 10% to about 40%, preferably from about 15% toabout 30%, and the ratio of the optional nonionic softener to DEQA isfrom about 1:6 to about 1:2, preferably from about 1:4 to about 1:2. Thelevel of optional nonionic softener in the liquid composition istypically from about 0.5% to about 10%, preferably from about 1% toabout 5%.

Preferred nonionic softeners are fatty acid partial esters of polyhydricalcohols, or anhydrides thereof, wherein the alcohol, or anhydride,contains from 2 to about 18, preferably from 2 to about 8, carbon atoms,and each fatty acid moiety contains from about 12 to about 30,preferably from about 16 to about 20, carbon atoms. Typically, suchsofteners contain from about one to about 3, preferably about 2 fattyacid groups per molecule.

The polyhydric alcohol portion of the ester can be ethylene glycol,glycerol, poly (e.g., di-, tri-, tetra, penta-, and/or hexa-) glycerol,xylitol, sucrose, erythritol, pentaerythritol, sorbitol or sorbitan.Sorbitan esters and polyglycerol monostearate are particularlypreferred.

The fatty acid portion of the ester is normally derived from fatty acidshaving from about 12 to about 30, preferably from about 16 to about 20,carbon atoms, typical examples of said fatty acids being lauric acid,myristic acid, palmitic acid, stearic acid and behenic acid.

Highly preferred optional nonionic softening agents for use in thepresent invention are the sorbitan esters, which are esterifieddehydration products of sorbitol, and the glycerol esters.

Sorbitol, which is typically prepared by the catalytic hydrogenation ofglucose, can be dehydrated in well known fashion to form mixtures of1,4—and 1,5-sorbitol anhydrides and small amounts of isosorbides. (SeeU.S. Pat. No. 2,322,821, Brown, issued Jun. 29, 1943, incorporatedherein by reference.)

The foregoing types of complex mixtures of anhydrides of sorbitol arecollectively referred to herein as “sorbitan.” It will be recognizedthat this “sorbitan” mixture will also contain some free, uncyclizedsorbitol.

The preferred sorbitan softening agents of the type employed herein canbe prepared by esterifying the “sorbitan” mixture with a fatty acylgroup in standard fashion, e.g., by reaction with a fatty acid halide orfatty acid. The esterification reaction can occur at any of theavailable hydroxyl groups, and various mono-, di-, etc., esters can beprepared. In fact, mixtures of mono-, di-, tri-, etc., esters almostalways result from such reactions, and the stoichiometric ratios of thereactants can be simply adjusted to favor the desired reaction product.

For commercial production of the sorbitan ester materials,etherification and esterification are generally accomplished in the sameprocessing step by reacting sorbitol directly with fatty acids. Such amethod of sorbitan ester preparation is described more fully inMacDonald; “Emulsifiers:” Processing and Quality Control:, Journal ofthe American Oil Chemists' Society, Vol. 45, October 1968.

Details, including formula, of the preferred sorbitan esters can befound in U.S. Pat. No. 4,128,484, incorporated hereinbefore byreference.

Certain derivatives of the preferred sorbitan esters herein, especiallythe “lower” ethoxylates thereof (i.e., mono-, di-, and tri-esterswherein one or more of the unesterified —OH groups contain one to abouttwenty oxyethylene moieties [Tweens®] are also useful in the compositionof the present invention. Therefore, for purposes of the presentinvention, the term “sorbitan ester” includes such derivatives.

For the purposes of the present invention, it is preferred that asignificant amount of di- and tri- sorbitan esters are present in theester mixture. Ester mixtures having from 20-50% mono-ester, 25-50%di-ester and 10-35% of tri- and tetra-esters are preferred.

The material which is sold commercially as sorbitan mono-ester (e.g.,monostearate) does in fact contain significant amounts of di- andtri-esters and a typical analysis of sorbitan monostearate indicatesthat it comprises about 27% mono-, 32% di- and 30% tri- andtetra-esters. Commercial sorbitan monostearate therefore is a preferredmaterial. Mixtures of sorbitan stearate and sorbitan palmitate havingstearate/palmitate weight ratios varying between 10:1 and 1:10, and1,5-sorbitan esters are useful. Both the 1,4- and 1,5-sorbitan estersare useful herein.

Other useful alkyl sorbitan esters for use in the softening compositionsherein include sorbitan monolaurate, sorbitan monomyristate, sorbitanmonopalmitate, sorbitan monobehenate, sorbitan monooleate, sorbitandilaurate, sorbitan dimyristate, sorbitan dipalmitate, sorbitandistearate, sorbitan dibehenate, sorbitan dioleate, and mixturesthereof, and mixed tallowalkyl sorbitan mono- and di-esters. Suchmixtures are readily prepared by reacting the foregoinghydroxy-substituted sorbitans, particularly the 1,4- and 1,5-sorbitans,with the corresponding acid or acid chloride in a simple esterificationreaction. It is to be recognized, of course, that commercial materialsprepared in this manner will comprise mixtures usually containing minorproportions of uncyclized sorbitol, fatty acids, polymers, isosorbidestructures, and the like. In the present invention, it is preferred thatsuch impurities are present at as low a level as possible.

The preferred sorbitan esters employed herein can contain up to about15% by weight of esters of the C₂₀-C₂₆, and higher, fatty acids, as wellas minor amounts of C₈, and lower, fatty esters.

Glycerol and polyglycerol esters, especially glycerol, diglycerol,triglycerol, and polyglycerol mono- and/or di- esters, preferably mono-,are also preferred herein (e.g., polyglycerol monostearate with a tradename of Radiasurf 7248). Glycerol esters can be prepared from naturallyoccurring triglycerides by normal extraction, purification and/orinteresterification processes or by esterification processes of the typeset forth hereinbefore for sorbitan esters. Partial esters of glycerincan also be ethoxylated to form usable derivatives that are includedwithin the term “glycerol esters.”

Useful glycerol and polyglycerol esters include mono-esters withstearic, oleic, palmitic, lauric, isostearic, myristic, and/or behenicacids and the diesters of stearic, oleic, palmitic, lauric, isostearic,behenic, and/or myristic acids. It is understood that the typicalmono-ester contains some di- and tri-ester, etc.

The “glycerol esters” also include the polyglycerol, e.g., diglycerolthrough octaglycerol esters. The polyglycerol polyols are formed bycondensing glycerin or epichlorohydrin together to link the glycerolmoieties via ether linkages. The mono- and/or diesters of thepolyglycerol polyols are preferred, the fatty acyl groups typicallybeing those described hereinbefore for the sorbitan and glycerol esters.

(F) Compositions

Other compositions that can contain the cationic polymers herein includethe “clear” compositions described in the copending U.S. patentapplication: Ser. Nos. 08/621,019; 08/620,627; 08/620,767; 08/620,513;08/621,285; 08/621,299; 08/621,298; 08/620,626; 08/620,625; 08/620,772;08/621,281; 08/620,514; and 08/620,958, all filed Mar. 22, 1996 and allhaving the title “CONCENTRATED, STABLE, PREFERABLY CLEAR, FABRICSOFTENING COMPOSITION”, all of said compositions being incorporatedherein by reference.

Other low softener, high perfume, compositions, disclosed in thecopending provisional application of Cristina Avila-Garcia, et al., Ser.No. 60/007,224, filed Nov. 3, 1995, for “Stable High Perfume, Low-ActiveFabric Softener Compositions”, said application being incorporatedhereinbefore by reference, can be prepared using the cationic polymersincluding: single strength liquid fabric softener compositions for usein the rinse cycle of a laundering process, the compositions comprising:

(a) from about 0.4% to about 5% cationic fabric softener;

(b) from about 0.3% to about 1.2% hydrophobic perfume;

(c) from about 0.4% to about 5% nonionic surfactant dispersibility aid;

(d) from 0% to about 1% water-soluble ionizable inorganic salt;

(e) from about 90% to about 98.5% water;

(f) an effective amount up to about 40%, of high boiling water solublesolvent;

(g) an effective amount, as disclosed hereinbefore of cationic polymerand

(h) from 0% to about 2% other ingredients; the ratio of cationicsoftener to perfume being from about 1:3 to about 5:1; the ratio ofcationic softener to nonionic surfactant being from about 1:2 to about4:1, and the amount of cationic softener plus nonionic surfactant beingfrom about 1% to about 7%. The compositions consist of a liquid aqueousphase with discrete hydrophobic particles dispersed substantiallyuniformly therein. The compositions preferably have a viscosity of fromabout 50 cp to about 500 cp.

(G) A Preferred Process for Preparation of Concentrated AqueousBiodegradable Textile Softener Compositions (Dispersions)

This invention also includes a preferred process for preparing aqueousbiodegradable quaternary ammonium fabric softenercompositions/dispersions containing cationic polymers providing asoftness improvement. Key to this invention is the incorporation of thecationic polymer into the aqueous phase of the dispersion, providingbetter performance for softening improvements and improved long termstability of the finished products.

For example, molten organic premix of the fabric softener active and anyother organic materials, except the cationic polymer, and, preferablynot the perfume, is prepared and dispersed into a water seat comprisingwater at about 145-175° F. High shear milling is conducted at atemperature of about 140-160° F. Electrolyte, as described hereinbefore,is then added in a range of from about 400 ppm to about 7,000 ppm asneeded to control viscosity. If the mixture is too viscous to millproperly, electrolyte can be added prior to milling to achieve amanageable viscosity. The dispersion is then cooled to ambienttemperature and the remaining electrolyte is added, typically in anamount of from about 600 ppm to about 8,000 ppm at ambient temperature.As a preferred method, perfume is added at ambient temperature beforeadding the remaining electrolyte.

Preferably, the cationic polymer is added to the dispersion after thedispersion has been cooled to ambient temperatures, e.g., 70-85° F. Morepreferably, the cationic polymer is added after ingredients such as soilrelease polymers and perfumes, and most preferably, the cationic polymeris added to the dispersion after the final addition of the electrolyte.

In the method aspect of this invention, fabrics or fibers are contactedwith an effective amount, generally from about 10 ml to about 150 ml(per 3.5 kg of fiber or fabric being treated) of the softener actives(including diester compound) herein in an aqueous bath. Of course, theamount used is based upon the judgment of the user, depending onconcentration of the composition, fiber or fabric type, degree ofsoftness desired, and the like. Preferably, the rinse bath contains fromabout 10 to about 1,000 ppm, preferably from about 50 to about 500 ppm,of the DEQA fabric softening compounds herein.

EXAMPLE I

Softness Benefits of the Use of Cationic Polymers

Ia Ib Ic Component Wt % Wt % Wt % Diester Compound¹ (83%) 28.20 28.2028.20 Hydrochloric Acid (1%) 1.50 1.50 1.50 DC 2310 Antifoam (10%) 0.250.25 0.25 CaCl₂ (2.5%) 8.00 8.00 8.00 Soil Release Polymer⁴ (40%) 1.251.25 1.25 DTPA⁵ acid solution (27.8%) 9.00 9.00 9.00 Perfume 1.28 1.281.28 Ammonium Chloride (25%) 0.40 0.40 0.40 CaCl₂ (25%) 1.60 1.60 1.60Cypro 514² (50%) — 0.40 — Magnifloc 587c³ (20%) — — 1.00 Blue Colorant(0.5%) 0.68 0.68 0.68 DI Water Balance Balance Balance pH 2.78 2.77 2.7Viscosity (cps) 25 50 30

The above compositions are made by the following process:

1. Separately heat the DI water to 155±5° F. and the Diester softenermix to 165±5° F.

2. Add the DC 2310 antifoam and the HCl to the water seat.

3. Add the Diester softener mix and mill with a high speed three stageIKA mill.

4. Add the 2.5% CaCl₂ solution with vigorous mixing.

5. Cool the product mix to ambient temperatures (approximately 70-80°F.).

6. In the order listed above (except water), add each remainingingredient with adequate mixing between each addition.

Controlled Softness Testing of Each Product is Performed with theFollowing Procedure

Wash Conditions

22 gallons of water, 95° F. wash, 62° F. rinse, and 14 min. normal washcycle. The same load was used in each case with 6 100% cotton terryfabric pieces included for softness evaluation.

Procedure

1) During the wash cycle, pour about 86 g of detergent (Tide powder)into the washer (about 22 gallons of water).

2) During the rinse cycle, when the rinse water is ⅓ in add about 30 g.of liquid fabric softener.

3) Dry the bundles for about 45 minutes (45 min. hot, 10 min. cooldown).

4) Remove softness terry fabric pieces for grading.

5) Grading is set up in a 2 treatment/8 repetitions pair test

6) Strip bundles by standard procedures in the washer

Results indicate the following (all scores in panelist score units (PSU)where 0=equal; 1=I think this one is better (unsure); 2=I know this oneis better; 3=This one is a lot better, and 4=This one is a whole lotbetter, versus a marketed control product used as an arbitrarystandard):

Δ PSU Product Test 1 Test 2 Average Ia +.90  +1.09 +1.00 Ib +1.41 +1.27+1.34 Ic +1.89 +1.64 +1.77

EXAMPLE II

Importance of Incorporating the Cationic Polymers into the Aqueous Phaseof the Fabric Conditioners for Stability

IIa IIb Component Wt % Wt % Diester Compound¹ (84.5%) 27.57 27.60 PEI1200E1⁶ in Oil Seat 3.00 — Hydrochloric Acid (25%) 0.12 0.12 DC 2310Antifoam (10%) 0.10 0.10 CaCl₂ (2.5%) 14.00 14.00 Soil Release Polymer⁴(40%) 1.25 1.25 PEI 1200E1⁶ acid solution (30%) — 9.00 Perfume 1.28 1.28CaCl₂ (25%) 0.68 0.68 Blue Colorant (10%) 0.05 0.05 Kathon CG (1.5%)0.02 0.02 DI Water Balance Balance pH 8.18 2.33 Viscosity (cps) 195 40Viscosity (cps) after 1 week at ambient >500 45

As can be seen, the addition of the cationic polymer to the softener(oil seat) results in product instability.

The above compositions are made by the following process:

1. Separately heat the DI water to 155±5° F. and a blend of the Diestersoftener mix and PEI 1200E1 to 165±5° F., mixing thoroughly afterheating, for IIa. Heat the Diester softener mix separately to 165±5° F.for formula IIb.

2. Add the DC 2310 antifoam and the HCl to the water seat and mix.

3. Add the Diester softener and PEI premix for IIa or the Diestersoftener premix for IIb into the water seat over 5-6 minutes. During theinjection, both mix (600-1,000 rpm) and mill (8,000 rpm with an IKAUltra Turrax T-50 Mill) the batch.

4. Add the 2.5% CaCl₂ solution with vigorous mixing.

5. Cool the product mix to ambient temperatures (approximately 70-80°F.).

6. In the order listed above (except water), add each remainingingredient with adequate mixing between each addition.

EXAMPLE III

Importance of Incorporating the Cationic Polymers into the Aqueous Phaseof the Fabric Conditioners for Softness

IIIa IIIb Component Wt % Wt % Diester Compound¹ (84.5%) 27.57 27.60Cypro 514² (50%) 0.40 0.40 Hydrochloric Acid (25%) 0.12 0.12 DC 2310Antifoam (10%) 0.10 0.10 CaCl₂ (25%) 14.00 14.00 Soil Release Polymer⁴(40%) 1.25 1.25 Perfume 1.28 1.28 CaCl₂ (25%) 0.68 0.68 Blue Colorant(10%) 0.05 0.05 Kathon CG (1.5%) 0.02 0.02 DI Water Balance Balance pH2.21 2.15 Viscosity (cps) 33 55 Softness grade versus marketed control(Δ PSU) −0.14 +0.73

The above compositions are made by the following process:

1. Separately heat the DI water to 155±5° F. and, for IIIa, a blend ofthe Diester softener mix and Cypro 514 to 165±5° F., is mixed thoroughlyafter heating, and for IIIb The Diester softener mix is heatedseparately to 165±5° F.

2. Add the DC 2310 antifoam and the HCl to the water seat and mix.

3. Add the Diester softener and Cypro 514 premix for IIIa or the Diestersoftener premix for IIIb into the water seat over 5-6 minutes. Duringthe injection, both mix (600-1,000 rpm) and mill (8,000 rpm with an IKAUltra Turrax T-50 Mill) the batch.

4. Add the 2.5% CaCl₂ solution with vigorous mixing.

5. Cool the product mix to ambient temperatures (approximately 70-80°F.).

6. In the order listed above(except water), and except for the Cypro 514for formula IIIb which is to be added after the soil release polymer,add each remaining ingredient with adequate mixing between eachaddition.

EXAMPLE IV

Softness Benefits of the Use of Cationic Polymers

IVa IVb IVc IVd Component Wt % Wt % Wt % Wt % Diester Compound¹ (84.5%)23.74 23.74 23.74 23.74 Hydrochloric Acid (1%) 2.15 2.15 2.15 2.15 DC2310 Antifoam (10%) 0.25 0.25 0.25 0.25 CaCl₂ (2.5%) 11.82 10.18 10.1810.18 Soil Release Polymer (40%) 1.08 2.15 2.15 2.15 PEI 1200 E1⁶ acidsolution — 10.00 — 10.00 (30%) Tinofix ECO⁷ (46.3%) — — 6.48 6.48Perfume 1.10 1.10 1.10 1.10 CaCl₂ (25%) 0.58 1.37 1.37 1.37 BlueColorant (0.5%) 0.33 0.33 0.33 0.33 DI Water Balance Balance BalanceBalance pH 2.68 2.59 2.77 2.58 Viscosity (cps) 28 20 25 20 Softnessgrade versus market +1.16 +1.59 +1.59 +1.81 control (Δ PSU))

The above compositions are made by the following process:

1. Separately heat the DI water to 155±5° F. and the Diester softenermix to 165±5° F.

2. Add the DC 2310 antifoam and the HCl to the water seat.

3. Add the Diester softener mix and mill with a high speed three stageTekmar mill.

4. Add the 2.5% CaCl₂ solution with vigorous mixing.

5. Cool the product mix to ambient temperatures (approximately 70-80°F.).

6. In the order listed above (except water), add each remainingingredient with adequate mixing between each addition.

EXAMPLE V

Va Vb Vc Component Wt % Wt % Wt % Diester Compound¹ (100%) 26.0 34.726.0 1,2-Hexanediol 17.0 22.0 — TMPD — — 15.0 1,4 Cyclohexanedimethanol— — 5.0 Hexylene Glycol 2.3 3.05 2.3 Ethanol 2.3 3.05 2.3 HCl (1N) 0.30.4 0.3 Cypro 514 0.2 0.5 0.2 Diethylenetriaminepentaacetic acid 0.010.01 0.01 Perfume 1.25 1.70 1.25 Kathon (1.5%) 0.02 0.02 0.02 Blue Dye0.003 0.003 0.003 DI Water 50.60 34.60 47.60

What is claimed is:
 1. Aqueous fabric softener composition comprising:(A) cationic fabric softening compound having the formula:(R)_(4−m)—N⁺—[(CH₂)_(n)—Y—R²]_(m)X⁻ wherein each Y═—O—(O)C—, —C(O)—O—,—NR—(O)C—, or —C(O)—NR—; m=2 or 3; each n=1 to 4; each R substituent isa short chain C₁-C₆ alkyl, hydroxyalkyl, or benzyl group or mixturesthereof; each R² is a long chain, C₁₁-C₂₁ hydrocarbyl, or substitutedhydrocarbyl substituent and the counterion, X⁻, is anysoftener-compatible anion; wherein said cationic fabric softeningcompound is in the composition in the form of vesicles; and (B) at leastan effective amount of cationic polymer to improve the softening of thecationic fabric softening compound, said cationic polymer being watersoluble to the extent of at least 0.5% by weight at 20° C. and having aconcentration in the aqueous phase of from about 0.001% to about 10%;wherein the vesicles are formed prior to introduction of the cationicpolymer into the composition.
 2. The composition according to claim 1wherein said cationic fabric softening compound has the structure:(R)_(4−m)—N⁺—[(CH₂)_(n)—Y—R²]_(m)X⁻ wherein each Y is —O—(O)C—, or—C(O)—O—; m is 2 or 3; n is 1 to 4; each R is a C₁-C₆ alkyl group,benzyl group, or mixtures thereof; each R² is a C₁₁-C₂₁ hydrocarbyl orsubstituted hydrocarbyl substituent; and X⁻ is any softener-compatibleanion; wherein the compound is derived from C₁₂-C₂₂ fatty acyl groupshaving an Iodine Value of from greater than about 5 to less than about140.
 3. The composition according to claim 2 wherein the iodine value isfrom about 40 to about
 130. 4. The composition according to claim 1wherein R² is derived from fatty acid containing at least 90% C₁₆-C₁₈chainlength.
 5. The composition according to claim 4 wherein the IodineValue is from about 60 to about
 130. 6. The composition according toclaim 1 wherein the level of the fabric softening compound is from about10% to about 50% and the molecular weight of the cationic polymer is fmabout 500 to about 1,000,000.
 7. The composition according to claim 6wherein the level of the fabric softening compound is from about 15% toabout 40% and the molecular weight of the cationic polymer is from about1,000 to about 250,000.
 8. The composition according to claim 7 whereinthe level of the fabric softening compound is from about 20% to about35% and the molecular weight of the cationic polymer is from about 2,000to about 100,000.
 9. The composition according to claim 1 wherein thecharge density of the cationic polymer is at least about 0.01 meq/gm.10. The composition according to claim 9, wherein the charge density ofthe cationic polymer is from about 0.1 to about 8 meq/gm.
 11. Thecomposition according to claim 10 wherein the charge density of thecationic polymer is from about 0.5 to about 7 meq/gm.
 12. Thecomposition according to claim 11 wherein the charge density of thecationic polymer is from about 2 to about 6 meq/gm.
 13. A stable liquidcomposition comprising: (A) from about 2% to about 60% of biodegradablequaternary ammonium fabric softening compound having the formula:(R)_(4−m)—N⁺—[(CH₂)_(n)—Y—R²]_(m)X⁻ wherein each Y═—O—(O)C—, —C(O)—O—,—NR—(O)C—, or —C(O)—NR—; m=2 or 3; each n=1 to 4; each R substituent isa short chain C₁-C₆ alkyl, hydroxyalkyl, or benzyl group or mixturesthereof; each R² is a long chain, C₁₁-C₂₁ hydrocarbyl, or substitutedhydrocarbyl substituent and the counterion, X⁻, is anysoftener-compatible anion; wherein said fabric softening compound is inthe composition in the form of vesicles; (B) 0.001% to about 10% ofcationic polymer in the aqueous phase, said cationic polymer being watersoluble to the extent of at least 0.5% by weight at 20° C.; wherein thevesicles are formed prior to introduction of the cationic polymer intothe composition; (C) from about 0% to about 5% of dispersibilitymodifier selected from the group consisting of:
 1. single-long-chainC₁₀-C₂₂ alkyl, cationic surfactant;
 2. nonionic surfactant with at least8 ethoxy moieties;
 3. amine oxide;
 4. C₁₂-C₂₅ fatty acid; and 5.mixtures thereof; (D) from about 0% to about 2% of a stabilizer; and (E)aqueous liquid carrier.
 14. The composition of claim 13, wherein thecationic polymer is present at a level of from about 0.1% to about 2%,and the pH is from about 2.8 to about 3.5.
 15. The composition of claim13, wherein the dispersibility modifier is selected from the groupconsisting of coco fatty acid, coco/tallow choline ester, and cocoamineoxide.
 16. The composition of claim 13, wherein the the quaternaryammonium fabric softening compound additionally comprises correspondingmonoester compound wherein the monoester compounds is less than about10% by weight of the mixed mono- and diester compounds.
 17. An aqueousfabric softening composition comprising: (A) a cationic fabric softeningcompound; and (B) at least an effective amount of cationic polymer toimprove the softening of the cationic fabric softening compound; whereinsaid cationic fabric softening compound is in the composition in theform of vesicles formed prior to the introduction of the cationicpolymer into the composition, and said cationic polymer has aconcentration in the aqueous phase of from about 0.001% to about 10%.18. A process for making an aqueous liquid softening composition ofclaim 7 comprising the steps of: (A) forming a premix of the organicingredients except for the cationic polymer and an acid water seatcontaining at least part of an acid; (B) adding the premix as a liquidinto said acid water seat and milling the premix and acid water seat;(C) optionally adding an electrolyte concentration aid prior to milling;(D) adding from about 400 ppm to about 7,000 ppm of an electrolyteconcentration aid after milling; and (E) adding said cationic polymerafter the addition of the electrolyte concentration aid.
 19. An aqueousfabric softening composition comprising: (A) a cationic fabric softeningcompound; and (B) at least an effective amount of cationic polymer toimprove the softening of the cationic fabric softening compound; whereinsaid cationic fabric softening compound is in the composition in theform of vesicles, and said cationic polymer is provided in thecomposition after formation of the vesicles and has a concentration inthe aqueous phase of from about 0.001% to about 10%.